Dodge - Neon - Workshop Manual - 1996 - 1996

Factory Workshop Manual Make Dodge Model Neon Engine and year L4-2.0L DOHC (1996) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Description and Operation ABS Main Relay: Description and Operation CIRCUIT OPERATION The system relay is used for the operation of the ABS system. Power for the relay is supplied on the B57 circuit from cavity 57 of the Controller Anti Lock Brake (CAB). Ground for the relay is on the Z1 circuit. This ground is spliced in with the pump motor and terminates at the left headlamp ground. When the system is operating normally power for the contact side of the relay is supplied from the CAB on the B57 circuit. It passes through the relay to the Z1 ground and terminates at the left headlamp ground. If a problem is detected in the system, the contact side of the relay switches from the Z1 to the F12 circuit. This causes the ABS warning lamp in the instrument cluster to illuminate. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Description and Operation Brake Fluid Pump Relay: Description and Operation CIRCUIT OPERATION The ABS pump motor relay controls when the pump motor runs. Power for the coil side of the relay is supplied from cavity 47 of the Controller Anti Lock Brake (CAB) on the B47 circuit. This circuit also supplies voltage for the contact side of the system relay The ground side of the coil is controlled by the B116 circuit. Circuit B116 connects to cavity 16 of the CAB connector. Circuit B120 from cavity 20 of the CAB connector powers the ABS pump motor. This circuit is also used as an input to the CAB for pump motor monitoring. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation Electronic Brake Control Module: Description and Operation Fig 1 Controller Anti-Lock Brake System (CAB) Fig 2 Controller Anti-Lock System (CAB) The Controller, Antilock Brake (CAB) located under the lefthand side of the instrument panel is a microprocessor device which monitors wheel speed and controls Antilock Brake System (ABS). The CAB monitors the speed of each wheel through the signals generated at the wheel speed sensors to determine if any wheel is beginning to lock. If any wheel lock is detected, the CAB commands the Hydraulic Control Unit (HCU) to modulate pressure to some or all of the hydraulic circuits. The CAB constantly monitors the ABS system for proper operation. If the CAB detects a fault, it will turn on the ABS warning lamp and disable the ABS braking system. The CAB contains a self-diagnostic program which will store system faults in a diagnostic program memory. There are multiple fault messages which may be stored in the CAB memory and can be displayed with a DRB or equivalent scan tool. These faults will remain in the CAB memory even after the ignition has been turned off. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Page 13 Electronic Brake Control Module: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect wiring harness 60-way connector from CAB. 3. Remove two CAB bracket to driver's side cowl mounting nuts. 4. Remove CAB from vehicle. 5. Reverse procedure to install, torque 60-way connector retaining bolt to 38 inch lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating Radiator Cooling Fan Control Module: Customer Interest Engine Cooling Fan - Vehicle Overheating NO: 07-01-97 GROUP: Cooling EFFECTIVE DATE: Mar. 28, 1997 SUBJECT: Vehicle Overheats And/or A/C Inoperative With No MIL Illumination MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Vehicle overheats (cold/warm weather) during stop and go driving or at an extended idle, and/or A/C becomes inoperative with no malfunction indicator light (MIL) illuminated. Radiator fans are not operating. DIAGNOSIS: Visually inspect the RFI connector and RFI filter module for signs of damage. If damage is found proceed to repair procedure. If no damage is found, proceed to cooling system diagnosis in the 1997 Neon Service Manual (Publication Number 81-270-7025) beginning on page 7-8. (See Illustration) PARTS REQUIRED: 1 04897717AA RFI Fan Filter Module 1 04897674AA Connector Package, Radiator Fan Motor REPAIR PROCEDURE: This bulletin involves the replacement of the RFI fan filter module and connector. 1. Record all radio pre-sets. 2. Disconnect the battery cables from the battery and body ground cable from the upper radiator closure panel (near center of car). 3. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Remove and set aside: - radiator-to-battery strut - battery thermo-guard - battery - battery tray - upper radiator mounts 4. Disconnect the left radiator fan motor. Remove and set aside the left radiator fan module assembly (two upper screws). 5. Disconnect the radiator fan motor feed wiring connector from the right fan motor RFI filter assembly (Illustration). 6. Remove the entire right radiator fan module assembly (two screws). Place the fan module assy face-down on a bench. Radiator Fan Motor Connector (On Vehicle): 7. Cut off the existing wiring connector directly behind the insulator and remove about 6 inches of tape. Slip the two fan wires from the convolute Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 23 tubing. 8. Stagger cut the two wires on the wire harness side approximately 2-1/2" apart. 9. Strip the insulation off the end of each wire on the wire harness approximately 1". 10. Stagger cut the matching wires on the new connector wiring assembly in the opposite order as you did on the vehicle wire harness side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 11. Strip the insulation off the end of each wire on the wire harness approximately 1". 12. Slide a piece of heat shrink tubing onto each wire of the connector wiring. 13. Connect the wire harness end to the connector wire end by twisting the ends together. Be sure to match colors - green to green and black to black. 14. Solder twisted wire ends using rosin core solder. 15. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 16. Slip the wires back into the convolute tubing. Wrap the entire uncovered convolute tubing with tape. RFI Fan Filter Module (On Bench): 17. Cut off the existing right motor wiring from the RFI filter module assy, and remove about four inches of sleeving. Remove the RFI filter assembly from the shroud (two screws) and discard the RFI filter. 18. Stagger cut the two wires from the motor approximately 2-1/2" apart. NOTE: CUT THE WIRES AWAY FROM THE ONE-TO-TWO WIRE SPLICES. 19. Strip an inch of insulation off the end of each wire from the motor. 20. Stagger cut the matching wires on the new RFI filter module wiring harness in the opposite order as you did on the motor wiring side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 21. Strip an inch of insulation off the end of each wire on the new RFI filter module wiring harness. 22. Slide a piece of heat shrink tubing onto each wire of the RFI filter module wiring harness wiring. 23. Connect each RFI filter module wiring harness end to each motor wire end by twisting the ends together. Be sure to match colors - blue to blue and black to black. 24. Solder twisted wire ends using rosin core solder. 25. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 26. Tape the wire harness over splices up to 1-1/2" behind the back of the RFI filter module box. Install the new RFI filter assembly to the shroud (one screw). 27. Reinstall the right radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.) 28. Install the new connector to the right fan motor RFI fan filter module assembly. Push in until the connector snaps into place. Slide the red tab sideways to lock the connector into place. 29. Re-install the left radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.). Route the RFI output wiring to the left fan motor, and install the connector to the left fan motor. Push in until the connector snaps into place. 30. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Install: - upper radiator mounts - battery tray - battery - battery thermo-guard Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 24 - radiator-to battery strut 31. Re-connect the body ground cable and battery cables. Torque body ground cable screw to 4.0 Nm (35 lb-in.) and battery terminals to 7.2 Nm (65 lb in.). Verify proper fan operation. 32. Reset all radio pre-sets recorded in step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-55-08-90 0.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating Radiator Cooling Fan Control Module: All Technical Service Bulletins Engine Cooling Fan - Vehicle Overheating NO: 07-01-97 GROUP: Cooling EFFECTIVE DATE: Mar. 28, 1997 SUBJECT: Vehicle Overheats And/or A/C Inoperative With No MIL Illumination MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Vehicle overheats (cold/warm weather) during stop and go driving or at an extended idle, and/or A/C becomes inoperative with no malfunction indicator light (MIL) illuminated. Radiator fans are not operating. DIAGNOSIS: Visually inspect the RFI connector and RFI filter module for signs of damage. If damage is found proceed to repair procedure. If no damage is found, proceed to cooling system diagnosis in the 1997 Neon Service Manual (Publication Number 81-270-7025) beginning on page 7-8. (See Illustration) PARTS REQUIRED: 1 04897717AA RFI Fan Filter Module 1 04897674AA Connector Package, Radiator Fan Motor REPAIR PROCEDURE: This bulletin involves the replacement of the RFI fan filter module and connector. 1. Record all radio pre-sets. 2. Disconnect the battery cables from the battery and body ground cable from the upper radiator closure panel (near center of car). 3. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Remove and set aside: - radiator-to-battery strut - battery thermo-guard - battery - battery tray - upper radiator mounts 4. Disconnect the left radiator fan motor. Remove and set aside the left radiator fan module assembly (two upper screws). 5. Disconnect the radiator fan motor feed wiring connector from the right fan motor RFI filter assembly (Illustration). 6. Remove the entire right radiator fan module assembly (two screws). Place the fan module assy face-down on a bench. Radiator Fan Motor Connector (On Vehicle): 7. Cut off the existing wiring connector directly behind the insulator and remove about 6 inches of tape. Slip the two fan wires from the convolute Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 30 tubing. 8. Stagger cut the two wires on the wire harness side approximately 2-1/2" apart. 9. Strip the insulation off the end of each wire on the wire harness approximately 1". 10. Stagger cut the matching wires on the new connector wiring assembly in the opposite order as you did on the vehicle wire harness side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 11. Strip the insulation off the end of each wire on the wire harness approximately 1". 12. Slide a piece of heat shrink tubing onto each wire of the connector wiring. 13. Connect the wire harness end to the connector wire end by twisting the ends together. Be sure to match colors - green to green and black to black. 14. Solder twisted wire ends using rosin core solder. 15. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 16. Slip the wires back into the convolute tubing. Wrap the entire uncovered convolute tubing with tape. RFI Fan Filter Module (On Bench): 17. Cut off the existing right motor wiring from the RFI filter module assy, and remove about four inches of sleeving. Remove the RFI filter assembly from the shroud (two screws) and discard the RFI filter. 18. Stagger cut the two wires from the motor approximately 2-1/2" apart. NOTE: CUT THE WIRES AWAY FROM THE ONE-TO-TWO WIRE SPLICES. 19. Strip an inch of insulation off the end of each wire from the motor. 20. Stagger cut the matching wires on the new RFI filter module wiring harness in the opposite order as you did on the motor wiring side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 21. Strip an inch of insulation off the end of each wire on the new RFI filter module wiring harness. 22. Slide a piece of heat shrink tubing onto each wire of the RFI filter module wiring harness wiring. 23. Connect each RFI filter module wiring harness end to each motor wire end by twisting the ends together. Be sure to match colors - blue to blue and black to black. 24. Solder twisted wire ends using rosin core solder. 25. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 26. Tape the wire harness over splices up to 1-1/2" behind the back of the RFI filter module box. Install the new RFI filter assembly to the shroud (one screw). 27. Reinstall the right radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.) 28. Install the new connector to the right fan motor RFI fan filter module assembly. Push in until the connector snaps into place. Slide the red tab sideways to lock the connector into place. 29. Re-install the left radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.). Route the RFI output wiring to the left fan motor, and install the connector to the left fan motor. Push in until the connector snaps into place. 30. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Install: - upper radiator mounts - battery tray - battery - battery thermo-guard Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 31 - radiator-to battery strut 31. Re-connect the body ground cable and battery cables. Torque body ground cable screw to 4.0 Nm (35 lb-in.) and battery terminals to 7.2 Nm (65 lb in.). Verify proper fan operation. 32. Reset all radio pre-sets recorded in step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-55-08-90 0.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations Radiator Fan Relay: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 35 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 36 Solid State Relay Solid State Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions Radiator Fan Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 39 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 40 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 41 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 42 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 43 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 44 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 45 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 46 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 47 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 48 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 49 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 50 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 51 Radiator Fan Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 52 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 53 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 54 Radiator Fan Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 55 Radiator Fan Relay: Electrical Diagrams Dual Cooling Fans A/C & Heater System -- Sheet 8w-42-4 Chrysler Does not provide a wiring diagram for dual fans on 95-98 model year Neons. This diagram is for the 99 model year and is presented for reference only. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 56 Air Conditioning/Heater (Part 3 Of 3) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Description and Operation > Radiator Fan Relay Description Radiator Fan Relay: Description and Operation Radiator Fan Relay Description Radiator Fan Relay-PCM Output The PCM energizes the radiator fan through the radiator fan relay. The PCM controls the ground circuit for the solenoid side of the relay. Buss bars in the Power Distribution Center (PDC) supply voltage to the solenoid side and contact side of the relay. The radiator fan power circuit contains a 30 amp fuse between the buss bar in the PDC and the radiator fan relay. The fuse is located in the PDC. When engine coolant reaches a temperature of 99°C (210°F), the PCM energizes the radiator fan. The PCM turns the fan OFF when coolant temperature drops to 93°C (199°F). Whenever the PCM energizes the A/C compressor clutch it engages the fan. Also, to prevent radiator steaming, the PCM energizes the radiator fan at idle following certain cold starts. The radiator fan relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. See: Diagrams/Connector Views Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Description and Operation > Radiator Fan Relay Description > Page 59 Radiator Fan Relay: Description and Operation Description of Trouble Codes High Speed Fan Relay Control Circuit Name of Code: High Speed Fan Control Relay Circuit When Monitored: With the ignition key in the run position and battery voltage above 10 volts. Set Condition: An open or shorted condition is detected in the high speed fan relay control circuit. Theory of Operation: The high speed fan relay controls the high speed operation of the radiator fans. The relay is located in the power distribution center. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the run position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay control circuit when the engine coolant temperature is too high and removes the ground when the temperature is acceptable. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - High speed fan relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module Rad Fan Control Relay Circuit Name of Code: Rad Fan Control Relay Circuit When Monitored: With the ignition key on, battery voltage greater than 10 volts, and the PCM requests the fans to be turned on. Set Condition: An open or shorted condition is detected in the Radiator Fan Control Relay Circuit. Theory of Operation: The solid state radiator fan relay controls the operation of the radiator fans. One connector of the relay is supplied with fused B(+) to power the fans. This same B(+) connection powers the internal electronics in the relay. The chassis ground connection (physical attachment to the chassis) on the relay provides a heat sink for the relay and a ground for the internal electronics. The ground connection from the relay connector is a redundant ground for the internal relay electronics. If the relay attachment to the chassis becomes loose or corroded the relay could fail due to its inability to dissipate heat through the chassis attachment. when the relay control circuit is grounded by the PCM, current flows through the relay to the fans. As the engine temperature rises to a preset level, the PCM will start sending a "Pulse Width Modulated" (PWM) ground signal to the relay. The dwell time of the signal will increase or decrease from 30% to 100% based on the engine coolant temperature and A/C pressures. this method of controlling the fans provides an infinitely variable fan speed. Possible Causes: - Relay Failure - Fused B(+) - Radiator fan relay control circuit open or shorted - PCM Failure - Connector terminals - Connector Wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Power Distribution (Part 1 Of 2) Fig. 15 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 67 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 68 Solid State Relay Solid State Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 69 Condenser Fan Motor Relay: Description and Operation Radiator Fan Relay-PCM Output The PCM energizes the radiator fan through the radiator fan relay. The PCM controls the ground circuit for the solenoid side of the relay. Buss bars in the Power Distribution Center (PDC) supply voltage to the solenoid side and contact side of the relay. The radiator fan power circuit contains a 30 amp fuse between the buss bar in the PDC and the radiator fan relay. The fuse is located in the PDC. When engine coolant reaches a temperature of 99°C (210°F), the PCM energizes the radiator fan. The PCM turns the fan OFF when coolant temperature drops to 93°C (199°F). Whenever the PCM energizes the A/C compressor clutch it engages the fan. Also, to prevent radiator steaming, the PCM energizes the radiator fan at idle following certain cold starts. The radiator fan relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. See: Relays and Modules - Cooling System/Radiator Fan Relay/Diagrams/Connector Views Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Description and Operation Battery Discharge Protection Relay: Description and Operation Halo Lamp/Time Delay Relay CIRCUIT OPERATION The time delay relay is used to allow a time-ON function for the ignition switch halo lamp. Power for the relay is received on the M1 circuit from the 10 Amp fuse located in the Power Distribution Center (PDC). This is the Ignition-Off Draw (IOD) fuse and HOT at all times. When a door is OPENED, or the headlamp switch is moved to the dome lamp position, a ground path is provided for the relay on the M2 circuit. This energizes the relay, CLOSING the contacts. When the relay contacts are CLOSED, power is provided through the relay to the M50 circuit. The M50 circuit supplies current to the ignition switch lamp in the steering column. Ground for the lamp is provided on the Z3 circuit. This circuit splices with the glove box lamp, the ash receiver lamp, and the PRNDL lamp. The Z3 circuit terminates at the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation Daytime Running Lamp Control Unit: Description and Operation CIRCUIT OPERATION On vehicles built for sale in Canada, the headlamps operate, at reduced intensity, when the ignition switch is in the RUN position and the parking brake switch is OPEN. In the Power Distribution Center (PDC), a bus bar connected to battery voltage feeds circuit A1. In the RUN position, the ignition switch connects circuit A1 to circuit A21. A 30 Amp fuse in the PDC, protects circuits A1 and A21. Circuit A21 connects to a bus bar in the fuse block. The bus bar in the fuse block feeds circuit G5 through a 5 Amp fuse in cavity 11. Circuit G5 is powered only when the ignition switch is in the RUN position. Circuit G9 connects to the DRL module. The G9 circuit splices to the brake warning switch, park brake switch and instrument cluster brake warning bulb. Circuit L20 from the headlamp and dimmer switch supplies battery voltage to the DRL module at all times. Circuit A3 from the PDC feeds circuit L20. A 40 Amp fuse in the PDC protects the A3 circuit. From the DRL module, circuit L4 powers the LOW beams of the left and right headlamps. The DRL controls the power to circuit L4. Circuit L4 connects to cavity 10 of the Daytime Running Lamp (DRL) module. Circuit L3 feeds the high beams of the headlamps. When the operator flashes the headlamps with the stalk of the multi-function switch, the DRL senses voltage on circuit L3. When it senses voltage on circuit L3, the DRL module stops supplying power to the low beams on circuit L4. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Power Distribution (Part 1 Of 2) Fig. 15 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 80 Horn Relay: Testing and Inspection The content of this article reflects changes called for in TSB 26-03-96. Horn Relay 1. Remove horn relay. 2. Using ohmmeter, test for continuity between ground and circuit 65 of horn relay. a. When the horn switch is not depressed, no continuity should be present. b. Continuity to ground when the horn switch is pdepressed. c. If continuity is not correct, repair the horn switch or wiring as necessary. 3. Insert a jumper wire between circuit 63 and 66 of the Power Distribution Center. a. If horn sounds, replace relay. b. If horn does not sound, install horn relay and refer to Horn Test. 4. Using voltmeter, test voltage at: a. Circuit 62 and 66 test for battery voltage from fuse C to body ground. b. If voltage is incorrect, repair as necessary. Refer to wiring diagrams. 5. Check relay for 70-75 ohms resistance from terminal 85 to 86. If resistance not OK, replace relay. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 81 Horn Relay: Service and Repair The content of this article reflects changes called for in TSB 26-03-96. Horn Relay 1. Remove power Distribution Center cover and locate the horn relay. 2. Remove the horn relay. Installation For installation, reverse above procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations Fuse/Fuse Block (Part 1 Of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Description and Operation Interior Lighting Relay: Description and Operation CIRCUIT OPERATION The time out relay is located in the fuse block and is used to control the ground path for various interior lamps. It will also turn the lamps OFF after a specified period of time, and works with the Remote Keyless Entry (RKE) system for illuminated entry. Circuit M2 connects to the relay and supplied a ground path through the door ajar switches. Circuit M1 is used to supply battery voltage to the relay. This circuit is produced by a 10 Amp fuse located in cavity 13 of the Power Distribution Center (PDC). Circuit M32 is connected from the relay to the various interior lamps and RKE module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 92 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Customer Interest for Powertrain Control Module: > 18-005-01 > Feb > 01 > PCM - OBDII Readiness Code Retention Powertrain Control Module: Customer Interest PCM - OBDII Readiness Code Retention NUMBER: 18-005-01 GROUP: Vehicle Performance DATE: Feb. 16, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-18-97, DATED MAY 9, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: OBDII Readiness Code Retention OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module. MODELS: 1995-1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (LH) Intrepid/Vision/Concorde/LHS 1996 (PL) Neon NOTE: THIS INFORMATION APPLIES TO FEDERAL EMISSION (SALES CODE NAA) AND CALIFORNIA EMISSION (SALES CODE NAE) MODELS BUILT PRIOR TO NOV. 21, 1995 (MDH1121XX) AND ALL 1995 JA MODELS EQUIPPED WITH A 2.0L ENGINE AND MANUAL TRANSAXLE. THE CALIFORNIA EMISSION MODELS ADDRESSED IN THIS BULLETIN WERE SOLD IN THE NORTHEAST STATES. CALIFORNIA MODELS SOLD IN CALIFORNIA WERE ADDRESSED WITH RECALL 678 DATED SEPT. 1996. DISCUSSION: The On Board Diagnostic (OBDII) system includes a monitor called readiness codes. The readiness codes indicate that all OBDII diagnostic tests have been performed and that diagnostic trouble codes (DTC's) can be read. It has been determined that the readiness codes may be cleared upon ignition key "OFF" cycles. Absence of readiness codes may cause owners to fail their emission inspection. To correct this condition, the Powertrain Control Module (PCM) must be reprogrammed. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING WITH CIS CD2075 OR HIGHER 1. Flash the PCM using the MDS2 (Mopar Diagnostic System) and DRBIII(R) (Scan Tool). NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Customer Interest for Powertrain Control Module: > 18-005-01 > Feb > 01 > PCM - OBDII Readiness Code Retention > Page 103 2. Type the necessary information on the Authorized Software Update Label p/n 04669020 (Fig. 1). Attach the label to the PCM and cover it 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: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Customer Interest for Powertrain Control Module: > 180696 > Feb > 96 > PCM - MIL ON/DTC's 84, 81, 27/9D Set Powertrain Control Module: Customer Interest PCM - MIL ON/DTC's 84, 81, 27/9D Set NO: 18-06-96 GROUP: Vehicle Performance DATE: Feb. 23, 1996 SUBJECT: Malfunction Indicator Light illuminated For Erroneous Hex DTC's 84, 81, 27 And/Or 9D MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 2.0L SOHC AND DOHC ENGINES (AUTOMATIC AND MANUAL TRANSAXLE) BUILT PRIOR TO NOVEMBER 14, 1995 (MDH 11-14-XX) IN THE BELVEDERE ASSEMBLY PLANT (D IN THE 11TH POSITION OF THE VIN) AND NOVEMBER 17, 1995 (MDH 11-17-XX) IN THE TOLUCA ASSEMBLY PLANT (T IN THE 11TH POSITION OF THE VIN). SYMPTOM/CONDITION: The Malfunction Indicator Light (MIL) will be illuminated and the following hex codes (DTC's) may be erroneously set: ^ 84 - TPS voltage does not agree with MAP. ^ 81 - Downstream 02 sensor stays at center. ^ 27 - No change in MAP from start to run. ^ 9D - Intermittent loss of cam or crank position. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If one of the above fault codes are set, verify proper operation as follows: ^ 84 - With key on and engine off, TPS voltage should increase smoothly from less than 1.0 volt at idle to greater than 3.0 volts at WOT. ^ 81 - Rear O2 signal - With the engine warmed up, verify that the rear O2 sensor voltage will read outside the .35 to .65 volt range during a road test, especially during hard deceleration and WOT. ^ 27 - MAP - With key on, check BARO; then start vehicle, verify that vacuum is greater than 4 inches of vacuum. ^ 9D - Cam & Crank - Verify cam and crank are in sync using the DRB III. If the above proper operation is not verified, proceed with the appropriate diagnosis and repair as stated in the Powertrain Diagnostic Procedures Manual prior to performing the software reflash contained in this bulletin. If the above proper operation is verified, proceed with the repair procedure. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 19 OR HIGHER AND TIL CD RELEASE 1099 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves reprogramming (flashing) the PCM with new software (calibrations). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Customer Interest for Powertrain Control Module: > 180696 > Feb > 96 > PCM - MIL ON/DTC's 84, 81, 27/9D Set > Page 108 5. Use the arrow keys and select PROGRAM VEHICLE CONTROLLER on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-44-95 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-005-01 > Feb > 01 > PCM OBDII Readiness Code Retention Powertrain Control Module: All Technical Service Bulletins PCM - OBDII Readiness Code Retention NUMBER: 18-005-01 GROUP: Vehicle Performance DATE: Feb. 16, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-18-97, DATED MAY 9, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: OBDII Readiness Code Retention OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module. MODELS: 1995-1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (LH) Intrepid/Vision/Concorde/LHS 1996 (PL) Neon NOTE: THIS INFORMATION APPLIES TO FEDERAL EMISSION (SALES CODE NAA) AND CALIFORNIA EMISSION (SALES CODE NAE) MODELS BUILT PRIOR TO NOV. 21, 1995 (MDH1121XX) AND ALL 1995 JA MODELS EQUIPPED WITH A 2.0L ENGINE AND MANUAL TRANSAXLE. THE CALIFORNIA EMISSION MODELS ADDRESSED IN THIS BULLETIN WERE SOLD IN THE NORTHEAST STATES. CALIFORNIA MODELS SOLD IN CALIFORNIA WERE ADDRESSED WITH RECALL 678 DATED SEPT. 1996. DISCUSSION: The On Board Diagnostic (OBDII) system includes a monitor called readiness codes. The readiness codes indicate that all OBDII diagnostic tests have been performed and that diagnostic trouble codes (DTC's) can be read. It has been determined that the readiness codes may be cleared upon ignition key "OFF" cycles. Absence of readiness codes may cause owners to fail their emission inspection. To correct this condition, the Powertrain Control Module (PCM) must be reprogrammed. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING WITH CIS CD2075 OR HIGHER 1. Flash the PCM using the MDS2 (Mopar Diagnostic System) and DRBIII(R) (Scan Tool). NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-005-01 > Feb > 01 > PCM OBDII Readiness Code Retention > Page 114 2. Type the necessary information on the Authorized Software Update Label p/n 04669020 (Fig. 1). Attach the label to the PCM and cover it 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: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 180696 > Feb > 96 > PCM MIL ON/DTC's 84, 81, 27/9D Set Powertrain Control Module: All Technical Service Bulletins PCM - MIL ON/DTC's 84, 81, 27/9D Set NO: 18-06-96 GROUP: Vehicle Performance DATE: Feb. 23, 1996 SUBJECT: Malfunction Indicator Light illuminated For Erroneous Hex DTC's 84, 81, 27 And/Or 9D MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 2.0L SOHC AND DOHC ENGINES (AUTOMATIC AND MANUAL TRANSAXLE) BUILT PRIOR TO NOVEMBER 14, 1995 (MDH 11-14-XX) IN THE BELVEDERE ASSEMBLY PLANT (D IN THE 11TH POSITION OF THE VIN) AND NOVEMBER 17, 1995 (MDH 11-17-XX) IN THE TOLUCA ASSEMBLY PLANT (T IN THE 11TH POSITION OF THE VIN). SYMPTOM/CONDITION: The Malfunction Indicator Light (MIL) will be illuminated and the following hex codes (DTC's) may be erroneously set: ^ 84 - TPS voltage does not agree with MAP. ^ 81 - Downstream 02 sensor stays at center. ^ 27 - No change in MAP from start to run. ^ 9D - Intermittent loss of cam or crank position. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If one of the above fault codes are set, verify proper operation as follows: ^ 84 - With key on and engine off, TPS voltage should increase smoothly from less than 1.0 volt at idle to greater than 3.0 volts at WOT. ^ 81 - Rear O2 signal - With the engine warmed up, verify that the rear O2 sensor voltage will read outside the .35 to .65 volt range during a road test, especially during hard deceleration and WOT. ^ 27 - MAP - With key on, check BARO; then start vehicle, verify that vacuum is greater than 4 inches of vacuum. ^ 9D - Cam & Crank - Verify cam and crank are in sync using the DRB III. If the above proper operation is not verified, proceed with the appropriate diagnosis and repair as stated in the Powertrain Diagnostic Procedures Manual prior to performing the software reflash contained in this bulletin. If the above proper operation is verified, proceed with the repair procedure. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 19 OR HIGHER AND TIL CD RELEASE 1099 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves reprogramming (flashing) the PCM with new software (calibrations). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 180696 > Feb > 96 > PCM MIL ON/DTC's 84, 81, 27/9D Set > Page 119 5. Use the arrow keys and select PROGRAM VEHICLE CONTROLLER on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-44-95 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 120 Powertrain Control Module: Specifications PCM 60-Way Connector Torque = 4 Nm (35 in lb) PCM Mounting Screws = 4 Nm (35 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 121 Fig. 100 Powertrain Control Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 124 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 125 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 126 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 127 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 128 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 129 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 130 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 131 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 132 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 133 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 134 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 135 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 136 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 137 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 138 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 139 Powertrain Control Module: Connector Views Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 140 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 141 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 142 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 143 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 144 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 145 Powertrain Control Module: Service Precautions - Before disconnecting any control module, make sure the ignition is off. Failure to do so could damage the module. - When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. - Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. - Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. - Operation of any type, including idling, should be avoided if engine misfiring occurs. Under this condition, the exhaust system operates at abnormally high temperature, which may cause damage to the catalyst or under-body parts of the vehicle. - Alteration or deterioration of ignition or fuel system, or any type of operating condition which results in engine misfiring must be corrected to avoid overheating the catalytic converter. - Proper maintenance and tune-up, according to manufacturer's specifications, should be made to correct abnormal conditions as soon as possible. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation Powertrain Control Module: Description and Operation Circuit Operation CIRCUIT OPERATION Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to cavity 46 of the Powertrain Control Module (PCM). A 20 Amp fuse in the PDC protects circuit A14. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 148 Powertrain Control Module: Description and Operation PCM Operation Fig. 100 Powertrain Control Module Fig. 3 Data Link Connector The Powertrain Control Module (PCM) is a digital computer containing a microprocessor (Fig. 2). The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. PCM Inputs: Air Conditioning Controls - Battery Voltage - Battery Temperature Sensor - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Fuel Level Sensor - Ignition Switch (A21) - Intake Air Temperature Sensor - Knock Sensor - Manifold Absolute Pressure (MAP) Sensor - Oxygen Sensors - Power Steering Pressure Switch - SCI Receiver - Speed Control Switches - Throttle Position Sensor - Transmission Park/Neutral Switch (Automatic Transmission) - Vehicle Speed Sensor PCM Outputs: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 149 - Air Conditioning Clutch Relay - Air Conditioning WOT Relay - Auto Shutdown (ASD) Relay - Charging Indicator Lamp - Data Link Connector - Duty Cycle EVAP Canister Purge Solenoid - EGR Solenoid - Fuel Injectors - Fuel Pump Relay - Generator Field - Idle Air Control Motor - Ignition Coils - Malfunction Indicator (Check Engine) Lamp - Radiator Fan Relay - Speed Control Solenoids - Tachometer - Torque Convertor Clutch Solenoid Based on inputs it receives, the PCM adjusts: Fuel Injector Pulse Width - Idle Speed - Ignition Spark Advance - Ignition Coil Dwell - EVAP Canister Purge Operation. The PCM Regulates: Cooling Fan - Air Conditioning - Speed Control System - Generator Charge Rate -- by Adjusting The Generator Field The PCM Also Performs Diagnostics The PCM adjusts injector pulse width (air-fuel ratio) based on: Battery Voltage - Coolant Temperature - Exhaust Gas Content (Oxygen Sensor) - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Manifold Absolute Pressure - Throttle Position The PCM adjusts ignition timing based on: Coolant Temperature - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Knock Sensor - Manifold Absolute Pressure - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) The PCM also adjusts engine idle speed through the idle air control motor based on: Air Conditioning Sense - Battery Temperature - Battery Voltage - Brake Switch - Coolant Temperature - Engine Speed (crankshaft Position Sensor) - Engine Run Time - Manifold Absolute Pressure - Power Steering Pressure Switch - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) - Vehicle Distance (Speed) ASD and Fuel Pump Relay Control Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 150 The Auto Shutdown (ASD) and fuel pump relays are mounted externally, but turned on and off by the PCM. Crankshaft Position (Engine Speed) Signal The crankshaft position sensor signal is sent to the PCM. If the PCM does not receive the signal within approximately one second of engine cranking, it deactivates the ASD relay and fuel pump relay When these relays deactivate, power is shut off from the fuel injectors, ignition coils, heating element in the oxygen sensors and the fuel pump. PCM Regulated Output Supply Voltages The PCM contains a voltage converter that changes battery voltage to a regulated 8 volts direct current to power: Camshaft Position Sensor - Crankshaft Position Sensor - Vehicle Speed Sensor The PCM also provides a 5 volt direct current supply for: Manifold Absolute Pressure Sensor - Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 151 Powertrain Control Module: Description and Operation PCM Related Trouble Code Messages Internal Controller Failure WHEN MONITORED With the ignition ON SET CONDITION There is an EPROM sum check failure at power down. THEORY OF OPERATION This code indicates the EPROM memory may be corrupt. PROBABLE CAUSES - Failed PCM PCM Failure EEPROM Write Denied Unsuccessful attempt to write to an EEPROM location by the PCM. PCM Failure SPI Communications WHEN MONITORED With the ignition ON. SET CONDITION Serial communications inside the controller fail eight times. THEORY OF OPERATION Communication between the microprocessors inside the PCM is needed to operate the total system. - A failure to communicate may cause improper actuation of the solenoids and relays. PROBABLE CAUSES - PCM failure PCM Failure SRI Mile Not Stored Unsuccessful attempt to update EMR mileage in the PCM EEPROM. 5 Volt Supply Output Too Low Name of Code: 5-Volt Supply Output Too Low When Monitored: With the ignition on. Set Condition: The 5-volt supply to the sensors is below 3.5 volts for 4 seconds. Theory of Operation: The powertrain control module maintains a 5-volt supply to the MAP sensor, TP sensor, and A/C pressure sensor. It is critical that the 5-volt supply stays between 4.8 volts and 5.1 volts as this input has a direct effect on the sensors' output voltages. Possible Causes: - Shorted 5-volt supply - Shorted sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview Circuit A14 connects to a bus bar in the PDC that the battery feeds. Circuit A14 powers the Automatic Shut Down (ASD) relay and fuel pump relay The A14 circuit also splices to the data link connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 154 Powertrain Control Module: Component Tests and General Diagnostics Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Page 155 Powertrain Control Module: Service and Repair Fig. 100 Powertrain Control Module NOTE: The PCM attaches to the inner fender panel next to the washer fluid bottle on the driver side (Fig. 100). REMOVAL 1. Disconnect negative cable from battery 2. Disconnect positive cable from battery. 3. Remove washer bottle neck. 4. Squeeze tabs on Power Distribution Center (PDC) while pulling PDC up to remove it from bracket. - Lay PDC aside to gain access to PCM bracket screws. 5. Remove screws attaching PCM to body. 3. Lift PCM up and disconnect the 2 40-way connector 7. Remove PCM. INSTALLATION 1. Attach the 2 40-way connector to PCM. 2. Install PCM. Tighten mounting screws to 4 Nm (35 in lb) torque. 3. Install PDC by pushing down into brackets. 4. Install washer bottle neck. 5. Connect positive cable to battery. 6. Connect negative cable to battery. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig. 15 Power Distribution Center (PDC) Auto Shutdown Relay The relay is located in the Power Distribution Center (PDC) (Fig. 15). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 159 Auto Shutdown Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Automatic Shut Down Relay Automatic Shut Down (ASD) Relay: Description and Operation Automatic Shut Down Relay Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. CIRCUIT OPERATION The Automatic Shut Down (ASD) relay is located in the Power Distribution Center (PDC). Power for the coil and contact side of the relay is supplied on circuit A14. This circuit is HOT at all times and protected by a 20 Amp fuse located in the PDC. The Powertrain Control Module (PCM) controls the ground path for the coil side of the relay on circuit K51. This circuit connects to cavity 67 of the PCM. When the PCM supplies the ground path on circuit K51 the contacts in the relay CLOSE connecting circuits A14 and A142. The A142 circuit is spliced and supplies power to the generator, fuel injectors, PCM, ignition coil, and heated oxygen sensors. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Automatic Shut Down Relay > Page 162 Automatic Shut Down (ASD) Relay: Description and Operation Related Trouble Codes and Set Conditions Auto Shutdown Relay Control Circuit Name of Code: Auto Shutdown Relay Control Circuit When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: An open or shorted condition is detected in the auto shutdown relay control circuit. Theory of Operation: The automatic shutdown relay (ASD) controls the 12 volt source to the fuel injectors, ignition coil(s), oxygen sensors, and the generator. The relay is located in the power distribution center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the run position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the run or crank position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the ASD relay control circuit ground. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - Auto shutdown relay control circuit open or shorted - Inoperative circuit driver in powertrain control module - PCM failure - Connector terminals - Connector wires No ASD Relay Output Sensed at PCM Name of Code: No Auto Shutdown (ASD) Relay Output Voltage At PCM When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: No voltage sensed at the powertrain control module when the auto shutdown relay is energized. Theory of Operation: When the ASD relay is energized, the relay contacts connect the fused B(+) circuit to the relay output circuit. The powertrain control module is connected in parallel with the ASD relay output circuit. This connection provides the PCM with a circuit to monitor the ASD relay output state. Whenever the PCM energizes the ASD relay, it checks the feedback circuit to ensure voltage is present at the ASD relay output. If voltage is not present, a trouble code is set. Possible Causes: - ASD relay output circuit open - Fused B(+) circuit open - ASD relay - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 Amp fuse located in the PDC. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 165 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 166 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 167 Automatic Shut Down (ASD) Relay: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 Fuel Pump Relay Fig. 15 Power Distribution Center (PDC) The fuel pump relay is located in the Power Distribution Center (PDC). The inside top of the PDC cover has a label showing relay and fuse location. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 172 Fuel Pump Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Fuel Pump Relay Operation Fuel Pump Relay: Description and Operation Fuel Pump Relay Operation NAME OF CODE: Fuel Pump Relay Control Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the fuel pump relay control circuit. THEORY OF OPERATION: The fuel pump relay controls the 12-volt source to the fuel pump. If the vehicle is equipped with a power distribution center, the relay is located in the Power Distribution Center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the RUN or CRANK position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the fuel pump relay control circuit ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Fuel pump relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Fuel Pump Relay Operation > Page 175 Fuel Pump Relay: Description and Operation Fuel Pump Relay Control Circuit Trouble Code Name of Code: Fuel Pump Relay Control Circuit When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: An open or shorted condition is detected in the fuel pump relay control circuit. Theory of Operation: The fuel pump relay controls the 12-volt source to the fuel pump. If the vehicle is equipped with a power distribution center, the relay is located in the PDC. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "run position". The circuit is completed when the other side of the relay coil is grounded by the powertrain control module. The PCM grounds the relay when the ignition switch is in either the run or crank position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the fuel pump relay control circuit ground. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - Fuel pump relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Page 176 Fuel Pump Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30 is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85 -- The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86 supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A -- When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87 When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Page 177 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Complete testing for this system or component can be found at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig. 15 Power Distribution Center (PDC) Auto Shutdown Relay The relay is located in the Power Distribution Center (PDC) (Fig. 15). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 181 Auto Shutdown Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Automatic Shut Down Relay Automatic Shut Down (ASD) Relay: Description and Operation Automatic Shut Down Relay Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. CIRCUIT OPERATION The Automatic Shut Down (ASD) relay is located in the Power Distribution Center (PDC). Power for the coil and contact side of the relay is supplied on circuit A14. This circuit is HOT at all times and protected by a 20 Amp fuse located in the PDC. The Powertrain Control Module (PCM) controls the ground path for the coil side of the relay on circuit K51. This circuit connects to cavity 67 of the PCM. When the PCM supplies the ground path on circuit K51 the contacts in the relay CLOSE connecting circuits A14 and A142. The A142 circuit is spliced and supplies power to the generator, fuel injectors, PCM, ignition coil, and heated oxygen sensors. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Automatic Shut Down Relay > Page 184 Automatic Shut Down (ASD) Relay: Description and Operation Related Trouble Codes and Set Conditions Auto Shutdown Relay Control Circuit Name of Code: Auto Shutdown Relay Control Circuit When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: An open or shorted condition is detected in the auto shutdown relay control circuit. Theory of Operation: The automatic shutdown relay (ASD) controls the 12 volt source to the fuel injectors, ignition coil(s), oxygen sensors, and the generator. The relay is located in the power distribution center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the run position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the run or crank position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the ASD relay control circuit ground. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - Auto shutdown relay control circuit open or shorted - Inoperative circuit driver in powertrain control module - PCM failure - Connector terminals - Connector wires No ASD Relay Output Sensed at PCM Name of Code: No Auto Shutdown (ASD) Relay Output Voltage At PCM When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: No voltage sensed at the powertrain control module when the auto shutdown relay is energized. Theory of Operation: When the ASD relay is energized, the relay contacts connect the fused B(+) circuit to the relay output circuit. The powertrain control module is connected in parallel with the ASD relay output circuit. This connection provides the PCM with a circuit to monitor the ASD relay output state. Whenever the PCM energizes the ASD relay, it checks the feedback circuit to ensure voltage is present at the ASD relay output. If voltage is not present, a trouble code is set. Possible Causes: - ASD relay output circuit open - Fused B(+) circuit open - ASD relay - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 Amp fuse located in the PDC. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 187 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 188 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 189 Automatic Shut Down (ASD) Relay: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Air Bag Replacement - Control Module Requirements Air Bag Control Module: Technical Service Bulletins Air Bag Replacement - Control Module Requirements NO: 08-04-96 GROUP: Electrical DATE: Feb. 9, 1996 SUBJECT: Air Bag Replacement - Control Module Requirements MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL 1996 NEON VEHICLES BUILT PRIOR TO 01-02-96 (MDH O1-02-xx). DISCUSSION: When replacing a passenger side airbag on 1996 Neon vehicles built prior to January 2, 1996, the airbag control module must also be replaced using P/N 5269907. If the control module is not replaced, the airbag warning light will illuminate when the ignition is turned on following service. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 195 Air Bag Control Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 196 Air Bag Control Module: Diagrams Airbag Control Module Connector -- 13 Way Airbag Control Module Connector -- 4 Way Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 197 Air Bag Control Module: Description and Operation OPERATION The ACM/Air Bag System Diagnostic Module (ASDM) contains safing sensor and energy reserve capacitor, while the ACM/Air Bag Electronic Control Module (AECM) contains impact sensor and energy reserve capacitor. The ACM monitors system to determine system readiness. The ACM will store sufficient energy to deploy air bag for two minutes after battery has been disconnected. The ACM contains an on board diagnostics function that will illuminate air bag warning lamp when a system fault occurs. CIRCUIT OPERATION Two different circuits supply battery voltage from the fuse block to the Airbag Control Module (ACM), F15 and F25. The F15 and F25 circuits are connected to separate bus bars internal to the fuse block. Different circuits from the Power Distribution Center (PDC) and ignition switch supply battery voltage to the fuse block bus bars. The F25 circuit supplies battery voltage to the ACM only when the ignition switch is in the RUN position. The F15 circuit powers the ACM when the ignition switch is in either the START or RUN position. An internal bus bar in the ignition switch connects the A1 circuit from the PDC to the A21 circuit when the switch is either the START or RUN position. The A21 circuit supplies battery voltage to the bus bar in the fuse block that feeds the F15 circuit. A 30 Amp fuse in the PDC protects the A1 and A21 circuits. A 10 Amp fuse in the fuse block, cavity 9, protects the F15 circuit. When the ignition switch is in the RUN position, it connects the A2 circuit from the PDC to the A22 circuit. The A22 circuit supplies battery voltage to the fuse block bus bar that feeds the F25 circuit. A 40 Amp fuse in the PDC protects the A2 and A22 circuits. A 10 Amp fuse in the fuse block, cavity 5, protects the F25 circuit. The ACM has a case ground and an external dedicated ground, circuit Z6. The dedicated ground connects to the instrument panel right center support. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 198 Air Bag Control Module: Service and Repair WARNING: The ACM contains a safing sensor which enables the system to deploy the airbags. To avoid accidental deployment, never connect ACM electrically to the system while vehicle battery is connected. Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components. CAUTION: Failure to follow the parking brake service procedures can result in damage to the parking brake mechanism. WARNING: The auto adjusting feature of this parking brake lever assembly contains a clock spring loaded to approximately 20 pounds. DO NOT release the auto adjuster lockout device before installing cables into the equalizer. Keep hands out of auto adjuster sector and pawl area. Failure to observe caution in handling this mechanism could lead to serious injury. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Manual transaxle only, remove shifter knob fastener and remove shifter knob. Fig 6 Attaching Screws At Rear Of Center Console With/Without Arm Rest Fig 7 Attaching Screws At Rear Of Center Console With Arm Rest 3. Remove screws attaching rear of center console assembly to console bracket. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 199 Fig 8 Attaching Screws At Front Of Center Console 4. Remove the two screws located in cup holders, attaching front of center console assembly to console bracket. 5. Raise park brake hand lever assembly as high as it will go for required clearance to remove center console. 6. Remove center console assembly from vehicle. WARNING: When repairs to the park brake hand lever assembly or cables is required, the auto adjuster must be reloaded and locked out. 7. Lower park brake lever handle. Fig 9 Locking Pin Installed In Park Brake Mechanism 8. Grasp park brake lever output cable by hand and pull upward. - Continue pulling on cable until a 3/16 in. drill bit can be inserted into handle and sector gear of park brake mechanism. - This will lock the park brake mechanism and take tension off park brake cables. Fig 10 Removing Park Brake Cables From Equalizer Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 200 9. Remove both rear park brake cables from the park brake cable equalizer. Fig 11 Brake Warning Lamp Connection To Park Brake Lever 10. Remove wiring harness electrical connector for brake warning light from park brake lever. Fig 12 Park Brake Lever Attachment To Console Bracket 11. Remove the two nuts attaching park brake lever to console bracket. Remove park brake lever mechanism from vehicle. Fig 13 Airbag Control Module 12. Remove module mounting nuts and remove module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 201 Fig 14 ACM Connectors 13. Disconnect ACM 4-way and 13-way connectors. 14. Remove Airbag Control Module. INSTALLATION 1. Connect both ACM connectors and ensure both connectors and all locking tabs are engaged. CAUTION: USE SUPPLIED SCREWS ONLY. 2. Position ACM (arrow pointing forward) in the console floor bracket, attach the nuts and tighten to 11 to 14 Nm (105 to 125 in lb) torque. NOTE: The park brake lever can be in any position when releasing the auto adjuster. To ease installation of center console, it is advisable to pull park brake lever handle all the way up before removing lockout pin. 3. Place park brake lever on console bracket. - Install and securely tighten the 2 attaching nuts. Fig 15 Park Brake Cables Properly Installed In Equalizer Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 202 Fig 16 Rear Park Brake Cable Installation On Equalizer 4. Install both rear park brake cables into equalizer on park brake lever output cable. 5. Ensure that park brake cable is correctly installed and aligned with cable track on park brake lever. 6. Pull park brake lever handle all the way up. Fig 17 Removing Lockout Pin From Park Brake Lever Assembly 7. Firmly grasp park brake lever locking pin and quickly remove it from the park brake lever mechanism. This will allow the park brake lever mechanism to correctly adjust the park brake cables. Fig 18 Brake Warning Lamp Connection To Park Brake Lever 8. Connect electrical connector for brake warning lamp onto terminal on park brake lever assembly. 9. Cycle park brake lever once to position park brake cables. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 203 - Then return the park brake lever its released position. - Check the rear wheels of the vehicle -- they should rotate freely without dragging. 10. Raise park brake lever to its fully engaged position. - This is necessary to allow installation of the center console. 11. Install center console assembly Fig 19 Attaching Screws At Rear Of Center Console With/without Arm Rest Fig 20 Attaching Screws At Rear Of Center Console With Arm Rest Fig 21 Attaching Screws At Front Of Center Console 12. Install the four center console assembly attaching screws. 13. Replace shifter knob and fastener. 14. Do not connect battery negative cable. Refer to Airbag System Check for proper procedure. See: Restraint Systems/Air Bag Systems/Testing and Inspection Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution (Part 1 Of 2) Fig. 15 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 208 Starter Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Left Door Switch Operation Power Door Lock Switch: Description and Operation Left Door Switch Operation Lock CIRCUIT OPERATION When the door lock switch is moved to the LOCK position, voltage is supplied on the P35 circuit to the bus bar located inside the right door switch, lock side. Battery voltage is passed through the switch to the P33 circuit to the door motors. Grounding is provided through the P34 circuit for all door motors back to the right door switch. The ground is passed through the bus bar internal to the switch, UNLOCK side, to the P36 circuit. The P36 circuit connects to the left front switch to a bus bar, internal to the switch, and then to the Z8 circuit. The Z8 circuit connects to its grounding point. Unlock CIRCUIT OPERATION When the switch is moved to the UNLOCK position, voltage is supplied on the P36 circuit to the right door switch, unlock side. The battery voltage is passed through the switch internal bus bar to the P34 circuit. The P34 circuit then connects to the door motors on the unlock side. Grounding for the UNLOCK function is provided by the P33 circuit. The P33 circuit connects back to the right door switch, LOCK side, and passes through the internal bus bar to the P35 circuit. The P35 circuit connects back to the left door switch, and passes through the switch to the Z8 circuit. The Z8 circuit goes to it's grounding point. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Left Door Switch Operation > Page 220 Power Door Lock Switch: Description and Operation Right Door Switch Operation Lock CIRCUIT OPERATION When the switch is moved to the LOCK position,voltage is supplied to the P33 circuit, and then to the door lock motors. The ground path is provided on the P34 circuit back to the right door switch. The ground is passed through the switch internal bus bar to the P36 circuit. The P36 circuit connects to the left door switch and through to the Z8 circuit. The Z8 circuit then connects to the grounding point at the left center instrument panel support. Unlock CIRCUIT OPERATION When the switch is moved to the UNLOCK position voltage is supplied to the P34 circuit from the switch to the door UNLOCK side of the motors. The grounding path is through the LOCK side of the motors, circuit P33, back to the switch. The ground continues through the internal bus bar of the switch on circuit P35 to the left door switch. At the left door switch, the ground passes through that switches internal bus bar to the Z8 grounding point. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation Power Mirror Switch: Description and Operation CIRCUIT OPERATION The power mirror switch has a right and left position. Moving the switch to either of these positions changes the voltage path internal to the switch (i.e.. changes polarity at the motors). When the switch is moved to the left position and mirror movement UP is selected, voltage is supplied through the P93 circuit and the ground path is through circuit P90. When the DOWN movement is selected the power and ground are reversed. If a left door mirror movement LEFT is selected voltage is supplied through the P95 circuit and the ground is passed through circuit P91. When the left door mirror RIGHT movement is selected the power and ground are reversed. When the switch is moved to the right position and mirror movement UP is selected, voltage is supplied through the P92 circuit and the ground path is through circuit P90. When the DOWN movement is selected the power and ground are reversed. If a right door mirror movement LEFT is selected voltage is supplied through the P94 circuit and the ground is passed through circuit P91. When the left door mirror RIGHT movement is selected the power and ground are reversed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 224 Power Mirror Switch: Testing and Inspection - Check the interior lamps 10 Amp fuse located in the PDC. - Circuit M1 supplies voltage to the radio, cargo lamp, underhood lamp, dome lamp, time delay relay, glove box lamp, and vanity lamps. Check for proper operation of these items. - Move the switch to its various positions and listen for the motors to click or try to move. Some movement or clicking indicated a poor connection or a mechanical problem with a mirror. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation Sunroof / Moonroof Switch: Description and Operation CIRCUIT OPERATION When the operator selects tilt OPEN circuit F1O is connected to circuit Q43. Circuit Q43 connects from the switch to the CLOSED vent limit switch in the sunroof module. The voltage is passed through the switch to circuit Q46. The Q46 circuit connects from the limit switch to the slide switch OPEN side. Power is passed through the switch to the Q41 circuit, then to the power sunroof motor. Ground is provided on circuit Q42 from the motor to the slide switch CLOSE side. The ground is passed through the bus bar in the switch to circuit Q45. The Q45 circuit connects from the slide switch to the tilt switch CLOSE side. Ground is passed through the switch to the Z5 circuit and to ground. When the operator selects the VENT CLOSE function, power and ground are reversed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Description and Operation Braking Sensor/Switch: Description and Operation CIRCUIT OPERATION Circuit L50 is an input to the Controller Anti Lock Brake (CAB). The L50 connects to cavity 13 of the CAB connector. Circuit L50 is spliced in with the stop lamps and is used to provide the CAB with information on when the brakes are being applied. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Testing and Inspection Parking Brake Warning Switch: Testing and Inspection In the START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) to circuit A41. A 30 Amp fuse protects circuits A1 and A41. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 239 39 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 240 43 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 241 45 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 242 47 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 243 51 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 244 55 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 245 57 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 246 59 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 247 63 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 248 67 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 249 69 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 250 71 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 251 173 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 252 177 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 253 179 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 254 181 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 255 187 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 256 191 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 257 193 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 258 195 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 259 201 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 260 205 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 261 207 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 262 209 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 263 256 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 264 Wheel Speed Sensor: Description and Operation OPERATION One wheel speed sensor (WSS) is located at each wheel and sends an AC signal to the Controller, Antilock Brake (CAB). The voltage is generated by magnetic induction when a tooth sensor ring passes by a stationary magnetic sensor. The CAB then converts the AC signal into digital signals for each wheel. The four wheel speed sensors are serviced individually. CIRCUIT OPERATION There are four wheel speed sensors, one at each wheel. The sensors use a tone wheel to determine wheel speed. Input to the Controller Anti Lock Brake (CAB) is done on the following circuits. All of these circuits are a twisted pair. B8 and B9 for the left front wheel (cavity 8 and cavity 9). B6 and B7 for the right front wheel (cavity 6 and cavity 7). B3 and B4 for the left rear wheel (cavity 3 and cavity 4). B1 and B2 for the right rear wheel (cavity 1 and cavity 2). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 265 Wheel Speed Sensor: Service and Repair Inspect tone wheel for missing or broken teeth, ensure tone wheel has not made contact with wheel speed sensor. Replace tone wheel if runout exceeds 0.010 inch. FRONT 1. Raise and support vehicle, then remove tire and wheel assembly. 2. Remove grommet retaining clip attaching screw, then pull sensor assembly grommet from fender shield. 3. Unplug speed sensor connector from vehicle wiring harness connector, then remove speed sensor cable routing bracket from front strut assembly. 4. Remove screw attaching speed sensor head to steering knuckle, then sensor from steering knuckle. Do not use pliers on sensor head, use a hammer and punch to tap edge of sensor ear, rocking sensor side to side until free. 5. Reverse procedure to install noting the following: a. Coat sensor head with high temperature multi-purpose E.P grease. b. Torque speed sensor head to 60 inch lbs. c. In two steps, torque wheel lug nuts to 95 ft. lbs. REAR 1. Disconnect battery ground cable. 2. Raise and support vehicle. 3. Remove rear tire and wheel assembly. 4. Remove clip attaching speed sensor cable connector to vehicle body, then disconnect speed sensor cable connector from vehicle wiring harness. 5. Remove speed sensor cable routing bracket from rear brake flex hose mounting bracket. 6. Remove speed sensor cable from routing clips on rear brake flex hose and chassis brake tube. 7. Remove speed sensor attaching bolt from drum brake support or disc brake adapter. 8. Remove speed sensor cable routing bracket attaching bolt from rear strut assembly. 9. Remove sensor head from support plate or adapter. Do not use pliers on sensor head, use a hammer and punch to tap edge of sensor ear, rocking sensor side to side until free. 10. Reverse procedure to install, torque speed sensor attaching bolt to 60 inch lbs. and wheel lug nuts to 80-110 ft. lbs.. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 18 Nm (165 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 271 Engine Coolant Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 272 Engine Coolant Temperature Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 273 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig.13 Engine Coolant Temperature Sensor-DOHC PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the intake manifold next to the thermostat housing (Fig. 13). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine cool and temperature gauge in the instrument cluster on circuit G20. See: Engine, Cooling and Exhaust/Cooling System/Lamps and Indicators Cooling System/Temperature Gauge/Description and Operation From circuit K2 the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics Coolant Temperature Sensor/Switch (For Computer): Component Tests and General Diagnostics Helpful Information The engine coolant temperature sensor is case grounded. The case ground provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Component Testing Fig. 80 Engine Coolant Temperature Sensor Location-DOHC 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 80). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 276 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.39 Engine Coolant Temperature Sensor-DOHC NOTE: The engine coolant temperature sensor threads into the rear of the cylinder head. New sensors have sealant applied to the threads. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. - Tighten to 18 Nm (165 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection Fig. 79 Stop Lamp Switch 1. Remove stop lamp switch assembly and disconnect connector. 2. Using a suitable ohmmeter, ensure there is continuity between switch terminals Nos. 5 and 6. When plunger is depressed, there should be continuity between terminals Nos. 1 and 2 and between terminals Nos. 3 and 4. 3. If above results are not obtained, switch is defective or out of adjustment. Switch is adjusted by pulling out plunger to end of travel which is approximately 3/4 inch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection > Page 281 Brake Switch (Cruise Control): Service and Repair 1. Depress brake pedal while rotating switch in a counterclockwise direction approximately 30° degrees. Pull switch out of bracket and disconnect wiring harness connector. Fig. 79 Stop Lamp Switch 2. Reverse procedure to install ensuring to pull switch plunger out to full length of travel and align switch with index key on bracket during installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Description and Operation Speed Control Switch: Description and Operation Name of Code: Speed Control Switch Always High When Monitored: With the ignition key on. Set Condition: An open condition is detected in the speed control on/off switch circuit. Theory of Operation: This circuit is monitored continuously by the PCM whenever the ignition is turned on. The trouble code sets if the voltage in this circuit is above 4.7 volts for more than 1 second. Possible Causes: - Mux switch circuit shorted to power - Mux switch circuit open - Open on/off switch - PCM failure Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Description and Operation > Page 285 Speed Control Switch: Testing and Inspection 1. Remove ON/OFF speed control switch assembly and disconnect connector. 2. Using a suitable ohmmeter, ensure there is no continuity between switch terminals. Press the OFF button and ohmmeter should read 0-0.5 ohms. Press the ON button and ohmmeter should read 15,245-15,555 ohms. If resistance does not fall within these values, replace switch. 3. Remove RESUME/SET/CANCEL speed control switch assembly and disconnect connector. 4. Using a suitable ohmmeter, ensure there is no continuity between switch terminals. Press the SET button and ohmmeter should read 2910-2970 ohms. Press the RESUME button and ohmmeter should read 6580-6750 ohms. Press the CANCEL button and ohmmeter should read 900-920 ohms. If resistance does not fall within these values, replace switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Description and Operation > Page 286 Speed Control Switch: Service and Repair The speed control switches are mounted in the steering wheel and wired through the clock spring device under the air bag module. 1. Ensure ignition switch is in OFF position. 2. Remove screws from each side of switch, then gently pull switch away from steering wheel assembly using a rocking motion. 3. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Locations Evaporator Temperature Sensor/Clutch Cycling Switch: Locations Evaporator Probe Location The evaporator probe is located in the Evaporator Case unit housing and placed in the evaporator fins. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions Evaporator Temperature Sensor/Clutch Cycling Switch: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 293 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 294 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 295 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 296 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 297 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 298 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 299 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 300 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 301 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 302 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 303 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 304 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 305 Evaporator Temperature Sensor/Clutch Cycling Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 306 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 307 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 308 Evaporator Temperature Sensor/Clutch Cycling Switch: Description and Operation EVAPORATOR PROBE The evaporator probe can be replaced without having to remove the unit housing from the vehicle. The evaporator probe is located in the unit housing and placed in the evaporator fins. the probe prevents evaporator freeze-up. This is done by cycling the compressor clutch OFF when evaporator temperature rises above freeze point. It cycles ON when the evaporator temperature rises above freeze point. The evaporator probe uses a thermistor probe in a capillary tube. The tube is inserted between the evaporator fins in the heater-A/C unit housing. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 309 Evaporator Temperature Sensor/Clutch Cycling Switch: Testing and Inspection CAUTION: The work area and vehicle must be between 16° C (60° F) and 32° C (90° F) when testing the switch. 1. Disconnect the three wire connector from the evaporator probe lead located behind the glove box. 2. Start engine and set A/C to low blower motor speed, panel, full cool, and RECIRC. Evaporator Probe Harness Connector 3. Using a voltmeter, check for battery voltage between Pin 1 and 2. If no voltage is detected, there is no power to the switch. Check wiring and fuses. 4. Using a voltmeter, check for battery voltage between Pin 1 and Pin 3. If no voltage is detected, there is no voltage from the Powertrain Control Module. If voltage is OK, connect a jumper wire between Pin 1 and Pin 3. The compressor clutch should engage. If the clutch engages, remove the jumper wire immediately and go to Step 5. If the compressor clutch does not engage, check the operation of the clutch and repair as necessary. 5. If compressor clutch engages, connect the evaporator probe 3-way connector. The compressor clutch should engage or cycle depending on evaporator temperature. If OK, go to Step 6. If not OK, replace the clutch cycling switch. 6. The engine running and the A/C set to: - Blower motor on low speed - Panel position - Full cool - RECIRC. - Close all doors and windows. Place a thermometer in the center discharge vent. 7. If the clutch does not begin to cycle off between 2° C to 7° C (35° F to 45° F), verify that the evaporator probe is fully installed and not loose in evaporator. If it is not properly installed, install probe and reset outlet temperature. If the evaporator probe is properly installed, replace the clutch cycling switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 310 Evaporator Temperature Sensor/Clutch Cycling Switch: Service and Repair REMOVAL NOTE: The evaporator probe can be replaced without having to remove the unit housing from the vehicle. 1. Disconnect probe wiring connector from behind the glove box. Evaporator Probe Location 2. Remove rubber grommet from evaporator blower module. 3. Note in which of the three pilot holes the evaporator probe is located. 4. Pull probe out of evaporator fins. INSTALLATION 1. There are three pilot holes available for the probe. The top hole is for service. If top hole was not used by previous probe, install probe in top hole. 2. If previous probe was removed from top hole, use a small plastic stick and make a new hole. Make the hole 1/4 inch above or below the original hole in the evaporator core. 3. Insert new probe into hole between evaporator fins. 4. Reinstall rubber grommet into evaporator probe access hole. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations High Pressure Cut Out Switch The high pressure cut out switch is located in the compressor manifold. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 315 High Pressure Sensor / Switch: Description and Operation HIGH PRESSURE CUT-OFF SWITCH The High Pressure Cut-Off Switch turns off the compressor if the system pressure exceeds 3240 kPa (470 psi). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 316 High Pressure Sensor / Switch: Service and Repair WARNING: The refrigerant must be removed from the system before removing the high pressure cut out switch. REMOVAL High Pressure Relief Valve 1. Disconnect wiring connector at the switch. 2. Remove internal snap ring. 3. Pull switch out of manifold. INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Low Pressure Sensor / Switch: Locations Low Pressure Cut Off Switch The low pressure cut off switch is located on the expansion valve. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 320 Low Pressure Sensor / Switch: Description and Operation LOW PRESSURE CUT-OFF SWITCH The Low Pressure Cut Off Switch monitors the refrigerant gas pressure on the suction side of the system. It turns off voltage to the compressor clutch coil when refrigerant gas pressure drops to levels that could damage the compressor. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 321 Low Pressure Sensor / Switch: Testing and Inspection CAUTION: The work area must not be below 21°C (70°F) to test the compressor clutch circuit. 1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Raise hood and disconnect low pressure cut off switch connector boot. 3. Using a suitable jumper wire, jump across the terminals inside wire connector boot. 4. If the compressor clutch does not engage, the cycling clutch switch, wiring, relay, or fuse can be defective. 5. If clutch engages, connect manifold gauge set. Read low pressure gauge. At pressure above 97 kPa (14 psi) and above, low pressure out off switch will complete the clutch circuit. If the low pressure gauge reads below 140 kPa (20 psi), the system is low on refrigerant charge or empty due to a leak. 6. Install connector boot on switch and repeat Step 3. If the clutch does not engage, replace the low pressure cut off switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 322 Low Pressure Sensor / Switch: Service and Repair The low pressure cut out switch is a sealed factory calibrated unit. It must be replaced if defective. WARNING: The refrigeration system must be completely recovered before proceeding with this operation. REMOVAL 1. Disconnect the boot like wire connector at the cut off switch. Low Pressure Cut Off Switch 2. Using a sender unit removal socket, remove the switch from the expansion valve. INSTALLATION NOTE: Verity the 0-ring condition on the replacement switch. For installation, reverse the above procedures. Evacuate and charge the system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove upper and lower steering column shrouds. 3. Remove combination switch mounting screws. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: Customer Interest Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 335 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: All Technical Service Bulletins Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 341 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > General Description Fuel Gauge Sender: Description and Operation General Description Fig. 10 Level Sensor Diagnosis OPERATION The fuel gauge sending unit is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and two variable resistors (tracks). These two tracks are used to send two different electrical signals. One is used for fuel gauge operation and the other is for OBD II emission requirements. Track 1 fuel gauge operation: As the fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge on the instrument panel to read full. As the fuel level decreases, the float and arm move down. This increases the sending unit resistance, causing the fuel gauge on the instrument panel to read empty Track 2-OBD II emission requirements: A variable voltage signal is sent to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes if the fuel level in the tank is less than 15 percent of its rated capacity. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > General Description > Page 346 Fuel Gauge Sender: Description and Operation Related Trouble Codes and Set Conditions Fuel Level Sending Unit Volts Too High Name of Code: Fuel Level Sending Unit Volts Too High When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes above a calculated value. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel systems monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Open sensor signal circuit - Fuel level sending unit failure - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Fuel Level Sending Unit Volts Too Low Name of Code: Fuel Level Sending Unit Volts Too Low When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes below 0.10 volts. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel system monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Sensor signal circuit shorted to ground - Fuel level sending unit failure - Loss of fuel ignition switch output voltage - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 347 Fuel Gauge Sender: Testing and Inspection Fig. 10 Level Sensor Diagnosis This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. To test the level sensor, connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector. Move the float lever to the positions shown in the resistance chart. Record the resistance at each point. Replace the level sensor if the resistance is not within specifications. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 348 Fuel Gauge Sender: Service and Repair Fig. 21 Fuel Pump/Level Sensor Electrical Connector NOTE: Remove fuel pump module prior to beginning this procedure. REMOVAL 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector. Fig. 22 Wire Terminal Locking Wedge 2. Pull off blue locking wedge. Fig. 23 Wire Terminal Locking Finger 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 349 Fig. 24 Removing Wires From Connector 4. Push level sensor signal and ground terminals out of the connector. Fig. 25 Loosening Level Sensor 5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Fig. 26 Level Sensor Removal/Installation 6. Push level sensor down slightly. - Ensure tab at bottom of sensor locks in place. 7. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 8. Install locking wedge on connector. 9. Push connector up into bottom of fuel pump module electrical connector. 10. Install fuel pump module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Testing and Inspection Parking Brake Warning Switch: Testing and Inspection In the START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) to circuit A41. A 30 Amp fuse protects circuits A1 and A41. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Transmission Connections Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 359 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 360 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 361 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 362 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 363 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 364 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 365 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 366 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 367 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 368 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 369 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 370 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 371 Backup Lamp Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 372 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 373 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 374 Rear Lighting (Part 1 Of 3) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Page 375 Backup Lamp Switch: Testing and Inspection Back-Up Lamp Switch The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 1. To test the switch, remove the wiring connector from the switch and test for continuity between the two outside pins. Continuity should only exist with the transaxle in the REVERSE position. 2. No continuity should exist from either pin to the transaxle case. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Automatic Transmission Backup Lamp Switch: Service and Repair Automatic Transmission Park/Neutral Starting and Back-Up Lamp Switch Removal 1. Place a suitable container under the switch to catch fluid when switch is removed. 2. Unscrew switch from transaxle case allowing fluid to drain into container. 3. Move selector lever to PARK, then NEUTRAL position and inspect to see the switch operating lever fingers are centered in the switch opening. Installation 1. Crew the switch with a new seal into the transaxle case and tighten to 33 Nm (24 ft. lbs.). 2. Test switch with a test lamp. 3. Add fluid to transaxle to bring up to proper level. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Automatic Transmission > Page 378 Backup Lamp Switch: Service and Repair Manual Transmission Back-Up Lamp Switch Removal 1. Lift vehicle on hoist. 2. From the bottom side of the vehicle, remove wiring connector from the switch. 3. Unscrew switch from the transaxle. Installation 1. To install, follow removal procedure in reverse order. Teflon tape or equivalent must be used on the switch threads. Tighten switch to 24 Nm (18 ft. lbs.). CAUTION: Do not overtighten switch. 2. Confirm back-up lamps are functioning properly following installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 382 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 383 Brake Light Switch: Service and Repair 1. Disconnect battery ground cable. 2. Depress brake pedal and rotate switch counterclockwise approximately 30°. 3. Pull switch rearward and remove from mounting bracket. 4. Disconnect wire connector from switch. 5. Pull switch plunger head out until ratchet sound stops. 6. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: Customer Interest Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 392 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: All Technical Service Bulletins Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 398 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch In OFF or PARKING Lamp Position Headlamp Switch: Description and Operation Headlamp Switch In OFF or PARKING Lamp Position CIRCUIT OPERATION Circuit A3 originates in the Power Distribution Center (PDC) and supplies battery voltage for the headlamp switch. A 40 Amp fuse protects the A3 circuit. The headlamp switch has an internal 24 Amp circuit breaker that connects circuit A3 to either the L2 or L20 circuits, depending on switch position. In the OFF and PARK positions the headlamp switch feeds the L20 circuit that connects to the multi-function switch. Circuit L20 powers the high beam circuit when the operator flashes the headlamps with the turn signal stalk of the multi-function switch. When the operator flashes the headlamps with the stalk, the multi-function switch connects the L20 circuit to the L3 circuit. The L3 circuit feeds the high beam of the headlamps. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch In OFF or PARKING Lamp Position > Page 403 Headlamp Switch: Description and Operation Headlamp Switch In ON Position CIRCUIT OPERATION When the headlamp switch is in the ON position, it connects the A3 circuit from the PDC to circuit L2. Circuit L2 connects to the multi-function switch and feeds the L4 circuit (for low beam operation). The L4 circuit connects to a bus bar in the fuse block. Circuits L43 and L44 connect to the bus bar in fuse block and power the low beam headlamps. Circuit L43 supplies voltage to the left headlamp. Circuit L44 supplies voltage to the right headlamp. Both the L43 and L44 circuits have separate 10 Amp fuses located in fuse block. Fuse 17 protects circuit L43, and fuse 18 protects circuit L44. When the operator selects high beam operation with the turn signal stalk of the multi-function switch, circuit L2 connects to the L3 circuit, Circuit L3 powers high beam operation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Page 404 Headlamp Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove steering column cover and liner. 3. Remove three screws securing headlamp switch mounting plate to instrument panel. 4. Pull headlamp switch assembly rearward from instrument panel opening. 5. Disconnect two electrical connectors from switch. Headlamp Switch Replacement 6. Depress button on bottom of switch, then pull control knob out of switch. 7. Unsnap headlamp switch bezel from mounting plate for access to retaining nut. 8. Remove retaining nut and mounting plate from switch. 9. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Horn Switch: Locations The horn switch is part of the Driver Airbag Module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 408 Horn Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO Restraint Systems / Air Bag Systems FOR STEERING WHEEL OR COLUMN REMOVAL PROCEDURES. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 409 Horn Switch: Description and Operation The content of this article reflects changes called for in TSB 26-03-96. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO Restraint Systems / Air Bag Systems FOR STEERING WHEEL OR COLUMN REMOVAL PROCEDURES. The horn switch is mounted between the outer and inner cover of the Driver Airbag Module. When the Driver Airbag is pressed the horn switch makes contact to ground. The ground signal is carried to the horn relay and the horn sounds. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 410 Horn Switch: Testing and Inspection The content of this article reflects changes called for in TSB 26-03-96. Horn Switch 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 Driver Airbag Module. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair 5. Using ohmmeter, connect one lead to the airbag module ground and the other lead to B+ wire. 6. Depress horn switch, and the meter should show continuity. If no continuity, replace the Driver Airbag Module. If OK, repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair Turn Signal Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove upper and lower steering column shrouds. 3. Remove combination switch mounting screws. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions Absolute Pressure Sensor: Technical Service Bulletins Emissions/Engine Controls - Service Manual Revisions NUMBER: 26-06-97E GROUP: Miscellaneous DATE: June, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1996 2.0L, 2.4L, 2.5L, 3.3L, 3.8L Engine Diagnostic Manual - Publication Number 81-699-96104 DESCRIPTION OF CHANGES Engine controls - revisions Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 420 501A Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 421 501B Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 422 501C Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 423 501D Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 424 502 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 425 645 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 426 645A Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 427 645B Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Battery Temp Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 431 Battery Temp Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 432 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > General Description Battery Temperature Sensor: Description and Operation General Description CIRCUIT OPERATION From circuit G31 the battery temperature sensor draws voltage from the Powertrain Control Module (PCM). The sensor is a variable resistor. As battery temperature changes, the resistance in the sensor changes causing a change in current draw. Circuit G31 connects to cavity 52 of the PCM connector. The PCM provides ground for the battery temperature sensor signal (circuit G31) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > General Description > Page 435 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor Operation Sensor External to the PCM Name of Code: Battery Temp Sensor (BTS) Voltage Either Too High or Too Low When Monitored: With the ignition key on. Set Condition: The PCM senses the voltage from the BTS to be either below 0.5 volts or above 4.9 volts for 3 seconds. Theory of Operation: The battery temp sensor voltage is used by the PCM to determine what the charging system goal should be. The PCM uses that goal to determine the charging output level. The battery temp sensor is external to the PCM. Possible Causes: - Battery temp sensor failure - Open circuit in battery temp sensor signal circuit - Short circuit in battery temp sensor signal circuit - PCM failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Battery Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 444 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 445 Camshaft Position Sensor: Locations Camshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 446 Camshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Operation Fig.9 Camshaft Position Sensor-DOHC PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity OPERATION Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 449 The camshaft position sensor attaches to the rear of the cylinder head (Fig. 9). 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 (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. The sensor also acts as a thrust plate to control camshaft endplay. CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the camshaft position sensor The K7 circuit connects to cavity 44 of the PCM connector. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 33 of the PCM connector. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 450 Camshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP Trouble Code Name of Code: Intermittent Loss of CMP or CKP When Monitored: During engine running. Set Condition: When the expected cam signal level disagrees with the actual cam signal level. Theory of Operation: After the engine has been started, the powertrain control module maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. Possible INTERMITTENT Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 451 Camshaft Position Sensor: Description and Operation No Cam Signal at PCM Trouble Code Name of Code: No Cam Signal at PCM When Monitored: During engine cranking, after a number of crank position sensor signals have been detected. Set Condition: Signals are not received from the camshaft position sensor when signals are received from the crankshaft position sensor Theory of Operation: The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. The PCM supplies 8 volts and a sensor ground to the CMP sensor. The camshaft position sensor signal circuit has a 5 volt pull-up from the PCM. The sensor signal is created by a rotating target magnet attached to the rear of the camshaft when the north pole of the magnet passes under the sensor, the signal remains at 5 volts. When the south pole passes under the sensor, the signal drops to 0.3 volt. Possible Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and target magnet - Damaged target magnet - Failed sensor - Failed PCM - Broken timing belt - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 454 Camshaft Position Sensor: Testing and Inspection Failure to Start Test This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 455 Camshaft Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Sensor Replacement Fig. 8 Camshaft Position Sensor Location Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head (Fig. 8). REMOVAL 1. Remove filtered air tube from the throttle body and air cleaner housing. 2. Disconnect electrical connector from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.35 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft (Fig. 35). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 458 Fig.36 Target Magnet Installation NOTE: The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft (Fig. 36). INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install filtered air tube. Tighten clamps to 3 Nm ±1 (25 in lb ±5) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 459 Camshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 18 Nm (165 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 463 Engine Coolant Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 464 Engine Coolant Temperature Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 465 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig.13 Engine Coolant Temperature Sensor-DOHC PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the intake manifold next to the thermostat housing (Fig. 13). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine cool and temperature gauge in the instrument cluster on circuit G20. See: Engine, Cooling and Exhaust/Cooling System/Lamps and Indicators Cooling System/Temperature Gauge/Description and Operation From circuit K2 the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics Coolant Temperature Sensor/Switch (For Computer): Component Tests and General Diagnostics Helpful Information The engine coolant temperature sensor is case grounded. The case ground provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Component Testing Fig. 80 Engine Coolant Temperature Sensor Location-DOHC 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 80). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 468 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.39 Engine Coolant Temperature Sensor-DOHC NOTE: The engine coolant temperature sensor threads into the rear of the cylinder head. New sensors have sealant applied to the threads. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. - Tighten to 18 Nm (165 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 473 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position Sensor Bolts ........................................................................................................ .......................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 474 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 475 Crankshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor-PCM Input Fig. 15 Crankshaft Position Sensor Fig. 14 Timing Reference Notches Fig.6 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60° signature notch (Fig. 14). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 478 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. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69° before top dead center (BTDC). - The second notch represents 49° BTDC. - The third notch represents 29°. - The last notch in each set represents 9° before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM connector. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 479 Crankshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP Trouble Code Name of Code: Intermittent Loss of CMP or CKP When Monitored: During engine running. Set Condition: When the expected cam signal level disagrees with the actual cam signal level. Theory of Operation: After the engine has been started, the powertrain control module maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. Possible INTERMITTENT Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 480 Crankshaft Position Sensor: Description and Operation No Crank Reference Signal at PCM Trouble Code Name of Code: No Crank Reference Signal at PCM When Monitored: During engine cranking, with battery voltage less than 11.5 volts and manifold vacuum present. Set Condition: No signal from the crankshaft position (CKP) sensor during engine cranking or there is a camshaft position sensor signal without a CKP sensor signal. Theory of Operation: The crankshaft position sensor is a hall-effect type sensor used to detect crankshaft speed and position. The PCM supplies 8 volts and a sensor ground to the CKP sensor. The crankshaft position sensor signal circuit has a 5-volt pull-up from the PCM. The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. When there isn't a notch under the sensor, the signal drops to 0.3 volt. Possible Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and crankshaft pulse ring - Damaged crankshaft pulse ring - Failed sensor - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 483 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 484 Crankshaft Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig. 12 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 12). 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Crankshaft Position Sensor Bolts torque ....................................................................................................................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 487 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection Fuel Level Sensor: Testing and Inspection Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications MAP Sensor Torque Aluminum Manifold = 3 Nm (30 in lbs) Plastic Manifold = 2 Nm (20 in lbs) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 494 Intake Air Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 495 Intake Air Temperature Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Fig.15 MAP/IAT Sensor-DOHC PURPOSE The intake air temperature sensor measures the temperature of the air as it enters the engine. The sensor supplies one of the inputs the PCM uses to determine injector pulse-width. CONSTRUCTION The MAP/Intake Air Temperature (IAT) sensor, located on the intake manifold, combines the MAP and Intake Air Temperature (IAT) functions into one sensor. CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. Circuit K21 connects to cavity 37 of the PCM connector. From circuit K21 the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor As intake air temperature changes the resistance in the sensor changes causing a change in current draw. The PCM provides ground for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor > Page 498 Intake Air Temperature Sensor: Description and Operation Intake Air Temp Sensor Voltage High Name of Code: Intake Air Temp Sensor Voltage High When Monitored: With the ignition on and the engine running. Set Condition: The intake air sensor circuit voltage at PCM cavity 37 goes above 4.9 volts. Theory of Operation: The intake air temperature sensor (IAT) is located in the intake manifold where it measures the temperature of the air that is about to enter the combustion chambers. The IAT is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. At high temperatures resistance decreases and the voltage will decrease. This allows the sensor to provide an analog voltage signal to PCM cavity 37. The PCM uses this signal to compensate for changes in air density due to temperature. Possible Causes: - Sensor signal circuit open - Sensor internally open - Sensor ground circuit open - Powertrain control module failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor > Page 499 Intake Air Temperature Sensor: Description and Operation Intake Air Temp Sensor Voltage Low Name of Code: Intake Air Temp Sensor Voltage Low When Monitored: With the ignition on and the engine running. Set Condition: The intake air sensor circuit voltage at PCM cavity 37 goes below 0.157 volt. Theory of Operation: The intake air temperature sensor (IAT) is located in the intake manifold where it measures the temperature of the air that is about to enter the combustion chambers. The IAT is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. At high temperatures resistance decreases and the voltage will decrease. This allows the sensor to provide an analog voltage signal to PCM cavity 37. The PCM uses this signal to compensate for changes in air density due to temperature. Possible Causes: - Sensor signal circuit shorted to ground - Sensor internally shorted - Powertrain control module failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Intake Air Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Helpful Information > Page 502 Intake Air Temperature Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 503 Intake Air Temperature Sensor: Service and Repair Map/Intake Air Temperature Sensor Fig. 98 MAP/IAT Sensor-DOHC NOTE: The MAP/IAT sensor attaches to the intake manifold plenum (Fig. 98). Fig. 97 Air Inlet Duct-DOHC REMOVAL 1. Remove air inlet duct wing nut and duct from intake manifold (Fig. 97). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 504 2. Disconnect the electrical connector from the MAP/IAT sensor. 3. Remove sensor mounting screws. 4. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seals. 2. Tighten mounting screws to 2 Nm (20 in lb) torque for a plastic manifold and 3 Nm (30 in lb) for a aluminum manifold. 3. Attach electrical connector to sensor 4. Install air inlet duct wing nut and duct from intake manifold, insure that the duct does not interfer with ignition cables. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 508 Knock Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 509 Knock Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation Knock Sensor: Description and Operation Knock Sensor Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 24 of the PCM connector. The PCM provides ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation > Page 512 Knock Sensor: Description and Operation Knock Sensor Circuit Trouble Code Name of Code: Knock Sensor Circuit When Monitored: With the ignition on and the engine running. Set Condition: The knock sensor circuit voltage falls below a minimum value at idle or deceleration, The minimum value is from a look-up table internal to the PCM and is based on engine rpm. The trouble code also sets if the sensor output is above 5.0 volts. Theory of Operation: The knock sensor is mounted on the cylinder block below the intake manifold. The knock sensor is comprised of thin piezo-electric ceramic discs bonded to a metal diaphragm. When engine knock occurs, the diaphragm vibrates along with the piezoelectric discs, producing an electrical signal. The signal is used by the PCM to adjust ignition timing to eliminate the knock condition. Possible Causes: - Sensor signal open - Sensor internally open - PCM failure - Sensor signal circuit shorted to ground - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Helpful Information Knock Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 515 Knock Sensor: Testing and Inspection Component Testing The knock sensor can be tested with a digital voltmeter. Sensor output should be between 80 mV and 4 volts with the engine running between 576 and 2,208 rpm. If the output falls outside of this range a DTC will be set. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 516 Knock Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Page 517 Knock Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications Manifold Pressure/Vacuum Sensor: Electrical Specifications The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications > Page 522 Manifold Pressure/Vacuum Sensor: Mechanical Specifications MAP Sensor Torque Aluminum Manifold = 3 Nm (30 in lbs) Plastic Manifold = 2 Nm (20 in lbs) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 523 Map Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 524 IAT/Map Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure Sensor Fig.15 MAP/IAT Sensor-DOHC OPERATION The PCM supplies 5 volts to the MAP sen son The MAP sensor function converts intake manifold pressure into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage increases proportionately. During cranking, before the engine starts running, the PCM determines atmosphenc air pressure from the MAP sensor voltage. While the engine operates, the PCM determines intake manifold pressure from the MAP sensor voltage. Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and the air/fuel mixture. The MAP/Intake Air Temperature Sensor (MAP/IAT) sensor mounts to the intake manifold. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Manifold Absolute Pressure (MAP) sensor. Circuit K6 connects to cavity 61 of the PCM connector. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity 36 of the PCM connector. The PCM provides ground for the MAP sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor > Page 527 Manifold Pressure/Vacuum Sensor: Description and Operation Related Trouble Codes & Set Conditions MAP Sensor Voltage Too High NAME OF CODE: MAP Sensor Voltage Too High WHEN MONITORED: With engine RPM above 400 but less than 1500 and the Throttle Position (TP) sensor voltage less than 1.0 volt. SET CONDITION: The manifold Absolute Pressure (MAP) sensor signal voltage is greater than 4.6 volts at start or with the engine running for 1.76 seconds. THEORY OF OPERATION: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to Powertrain Control Module (PCM) cavity 36. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at deep throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 61; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Open 5-volt supply circuit - Sensor open internally - Sensor ground circuit - Sensor signal circuit shorted to voltage - Failed PCM - Connector terminals - Connector wires MAP Sensor Voltage Too Low Name of Code: MAP Sensor Voltage Too Low When Monitored: With engine rpm above 400 but less than 1,500 and the TP sensor voltage less than 1.0 volt. Set Condition: The MAP sensor signal voltage is below 1.2 volts at start, or below 0.02 volt for 1.76 seconds with engine running. Theory of Operation: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to PCM cavity 36. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at deep throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 61; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 43. Possible Causes: - Open 5-volt supply circuit - Signal circuit shorted to ground - Failed sensor - PCM failure - Connector terminals - Connector wires No Change In MAP From Start to Run NAME OF CODE: No Change in MAP From Start to Run WHEN MONITORED: With engine RPM above 400 but less than 1500 and the throttle body at closed throttle. SET CONDITION: Too small a difference is seen between barometric pressure at ignition on and manifold vacuum (engine running) for 1.76 seconds. THEORY OF OPERATION: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor > Page 528 Powertrain Control Module (PCM) cavity 36. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at deep throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 61; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Restricted or leaking vacuum/pressure to MAP sensor - Ice in sensor or passage - Failed sensor - Failed PCM TPS Voltage Does Not Agree With MAP Name of Code: TPS Voltage Does Not Agree with MAP When Monitored: With the engine running and no MAP sensor or TP sensor trouble codes. Set Condition: The powertrain control module (PCM) performs two separate tests on the TP sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 mph and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 4 continuous seconds. Theory of Operation: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from the PCM. The sensor ground is provided by the PCM. Possible Causes: - Failed powertrain control module - Connector wires - TP sensor failure - Vehicle speed - Mechanical failure - MAP sensor - Connector terminals Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing Manifold Pressure/Vacuum Sensor: Testing and Inspection Component Testing Fig. 82 MAP Sensor Connector CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 1 and 4 (Fig. 82). With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. If OK, go to next step. - If not OK, go to step 3. 2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness condition. Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 43. - If OK, go to next step. - If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 3 and 1 with the key ON. The voltage should be approximately 5 volts ± 0.5V). Five volts (± 0.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor. - If not OK, repair or replace the wire harness as required. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing > Page 531 Manifold Pressure/Vacuum Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing > Page 532 Manifold Pressure/Vacuum Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 533 Manifold Pressure/Vacuum Sensor: Service and Repair Map/Intake Air Temperature Sensor Fig. 98 MAP/IAT Sensor-DOHC NOTE: The MAP/IAT sensor attaches to the intake manifold plenum (Fig. 98). Fig. 97 Air Inlet Duct-DOHC REMOVAL 1. Remove air inlet duct wing nut and duct from intake manifold (Fig. 97). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 534 2. Disconnect the electrical connector from the MAP/IAT sensor. 3. Remove sensor mounting screws. 4. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seals. 2. Tighten mounting screws to 2 Nm (20 in lb) torque for a plastic manifold and 3 Nm (30 in lb) for a aluminum manifold. 3. Attach electrical connector to sensor 4. Install air inlet duct wing nut and duct from intake manifold, insure that the duct does not interfer with ignition cables. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Upstream and Downstream Heated Oxygen Sensors Torque = 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 540 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 541 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 542 Downstream Oxygen Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 543 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor Oxygen Sensor: Description and Operation Heated Oxygen Sensor CIRCUIT OPERATION Circuit A14 is a bus bar in the Power Distribution Center (PDC), and connects to battery voltage. The contact side of the Automatic Shut Down (ASD) relay connects circuit A14 and circuit A142. A 20 Amp fuse in the PDC protects circuits A14 and A142. Circuit A14 also supplies voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) controls the ground path circuit for the coil side of the ASD relay on circuit K51. Circuit K51 connects to cavity 67 of the PCM connector. Circuit A142 splices to supply voltage for the upstream and downstream heated oxygen sensors. The A142 circuit also splices to cavity 6 of the PCM. The input provided by circuit A142 at cavity 6 tells the PCM that the ASD relay energized. Circuit K41 delivers the signal from the upstream heated oxygen sensor to the PCM. Circuit K41 connects to cavity 30 of the PCM connector. Circuit K141 delivers the signal from the down-stream heated oxygen sensor to the PCM. Circuit K141 connects to cavity 51 of the PCM connector. The PCM provides a ground for the upstream and downstream heated oxygen sensor signals (circuit K41 and K141) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector Circuit Z1 provides ground for the heater circuits in each sensor. Circuit Z1 terminates at the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor > Page 546 Oxygen Sensor: Description and Operation Related Trouble Codes & Set Conditions Downstream O2 Sensor Heater Failure Name of Code: Downstream O2 Sensor Heater Failure When Monitored: With the ignition key oft, after the engine cools down Set Condition: No sensor output signal is received when the PCM powers up the sensor heater. Theory of Operation: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this 02 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases the downstream oxygen sensor tells the PCM how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. This O2 sensor serves as an indicator of oxygen content. The heater element helps the O2 sensor quickly reach a normal and steady operating temperature, which is required for proper emission control. Possible Causes: - Open heater element circuit - O2 sensor failure - Powertrain control module failure - Connector terminals - Connector wires Downstream O2 Sensor Shorted to Ground Name of Code: Downstream O2S Voltage Shorted To Ground When Monitored: With the ignition key off, after the engine cools down. Set Condition: The downstream oxygen sensor signal voltage is below 0.156 volt prior to O2 sensor heater test. Theory of Operation: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the PCM how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. Variations in the signal from the O2 sensor serve as an indicator of oxygen content. The catalytic converter absorbs the oxygen in the exhaust gas when the fuel/air mixture is lean. The downstream 02 sensor indicates a deficiency of oxygen when the upstream 02 sensor detects an abundance of oxygen and vice versa. Possible Causes: - Sensor output wire shorted to another circuit - Dirty connection causing voltage tracking in connector - O2 sensor failure - Powertrain control module failure - Connector terminals/wires Downstream O2 Sensor Shorted to Voltage Name of Code: Downstream O2 Sensor Shorted To Voltage When Monitored: With the ignition key on. Set Condition: The engine running for more than 2 minutes and coolant temp. above 176°F. The upstream oxygen sensor signal voltage is above 1.2 volts for 2.6 seconds. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor > Page 547 Theory of Operation: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. Possible Causes: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure - Powertrain control module failure - Connector terminals - Connector wires Downstream O2 Sensor Stays at Center Name of Code: Downstream O2 Sensor Stays At Center When Monitored: With the vehicle engine running for more than two minutes, engine temperature greater than 170°F, in closed loop. Set Condition: If oxygen sensor voltage stays between 0.29 volts and 0.72 volts for 30 seconds, the PCM pulls the sensor voltage to 5.0 volts for 60 seconds and monitors the sensor voltage. If the voltage stays at 5.0 volts, this trouble code will set, indicating no activities. Theory of Operation: Effective control of exhaust emissions is achieved by an oxygen feedback system. The downstream oxygen sensor (O2S), located in the exhaust path, monitors the exhaust emissions. Once the sensor reaches its normal operating temperature of 300°-350° C (572°-662° F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the efficiency of the catalytic converter. The downstream oxygen sensor is monitored for proper response to assure a correct catalytic converter efficiency calculation. A good sensor will indicate a rich condition when at WOT (due to the enriched F/A ratio), and a lean condition when in decel fuel shut-off (due to the lean F/A ratio). Possible Causes: - Sensor output wire open - Dirt/moisture/grease inside connector - Open ground circuit - Oxygen sensor failure - PCM failure Slow Upstream O2 Sensor During Catalyst Monitor Name of Code: Slow Upstream O2 Sensor During Catalyst Monitor When Monitored: With the engine running, coolant greater than 17O°F, open throttle, steady to slightly increasing vehicle speed between 18 MPH and 55 MPH, with a light load on the engine, for a period no less than five minutes. Set Condition: The upstream oxygen sensor signal voltage is switching from below 0.39 volt to above 0.6 volt and back fewer times than required. Theory of Operation: Effective control of exhaust emissions is achieved by an oxygen feedback system, of which the most important element is the upstream oxygen sensor (O2S). which is located in the exhaust path. Once the sensor reaches its normal operating temperature of 30O° to 350°C (572° to 662°F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the fuel injector pulse width, which maintains the optimum 14.7 to 1 air/fuel (A/F) ratio that is required for the catalytic converter to best control exhaust emissions. Response rate is the time required for the sensor to detect changes in the exhaust gas oxygen content; it switches from lean to rich if it is exposed to a richer than optimum A/F mixture, or vice versa. The O2S output voltage ranges from 0 to 1 volt. A good sensor easily generates an output voltage in this range as it is exposed to different oxygen concentrations. To detect a shift in the A/F mixture (lean or rich), the output voltage has to change beyond a threshold value. A malfunctioning sensor could have difficulty changing beyond the thresholds. Possible Causes: - Exhaust leak Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor > Page 548 - Dirt/moisture/grease inside connector - Fuel contamination - Engine mechanical - Weak upstream O2 sensor with deteriorated catalyst Upstream O2 Sensor Heater Failure Name of Code: Upstream O2 Sensor Heater Failure When Monitored: With the Ignition key off, after the engine cools down. Set Condition: No sensor output signal is received when the PCM powers up the sensor heater. Theory of Operation: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases. the upstream oxygen sensor tells the PCM how well its output signal is controlling the air/fuel ratio. Variations in the signals from the O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/ fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. The heater element helps the 02 sensor quickly reach a normal and steady operating temperature. which is required for proper emission control. Possible Causes: - Open heater element circuit - 02 sensor failure - PCM failure - Dirt/moisture/grease inside connector - 02 sensor heater wires - ASD relay failure Upstream O2 Sensor Shorted to Voltage Name of Code: Upstream 02 Sensor Shorted to Voltage When Monitored: With the ignition key on. Set Condition: The engine running for more than 2 minutes and coolant temperature above 176°F. The upstream oxygen sensor signal voltage is above 1.2 volts for 2.6 seconds. Theory of Operation: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. Possible Causes: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - 02 sensor failure - Powertrain control module failure - Connector terminals - Connector wires Upstream O2 Sensor Slow Response Name of Code: Upstream O2 Sensor Slow Response When Monitored: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor > Page 549 With the engine running for more than 3 minutes, engine temperature greater than 120°F, after reaching a vehicle speed of 20 mph for 120 seconds, at idle with the transmission in drive (auto) or in neutral (manual). Set Condition: The upstream oxygen sensor signal voltage is switching from below 0.39 volt to above 0.6 volt and back fewer times than required. Theory of Operation: Effective control of exhaust emissions is achieved by an oxygen feedback system, of which the most important element is the upstream oxygen sensor (O2S), which is located in the exhaust path. Once the sensor reaches its normal operating temperature of 300°C-350°C (572°F - 662°F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the fuel injector pulse width, which maintains the optimum 14.7 to 1 air/fuel (A/F) ratio that is required for the catalytic converter to best control exhaust emissions. Response rate is the time required for the sensor to detect changes in the exhaust gas oxygen content; it switches from lean to rich if it is exposed to a richer than optimum A/F mixture, or vice versa. The O2S output voltage ranges from 0 to 1 volt. A good sensor easily generates an output voltage in this range as it is exposed to different oxygen concentrations. To detect a shift in the A/F mixture (lean or rich), the output voltage has to change beyond a threshold value. A malfunctioning sensor could have difficulty changing beyond the thresholds. Possible Causes: - Exhaust leak - Dirt/moisture/grease inside connector - Fuel contamination - Engine mechanical Upstream O2 Sensor Stays at Center Name of Code: Upstream O2 Sensor Stays at Center When Monitored: With the engine running for more than 2 minutes and engine temperature greater than 17O°F. Set Condition: The upstream oxygen sensor signal voltage is between 0.35 volts and 0.55 volts for 1.5 minutes. Theory of Operation: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this 02 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. Possible Causes: - Sensor output wire open - O2 sensor failure - PCM failure - Dirt/moisture/grease causing voltage tracking in connector - Connector wires Upstream O2S Voltage Shorted to Ground Name of Code: Upstream 02S Voltage Shorted To Ground When Monitored: With engine coolant temperature above 170°F on the previous key on, after a cold start, engine coolant below 98°F, and ambient/ battery sensor reading within 27°F of engine coolant. Set Condition: The upstream oxygen sensor signal voltage is below 0.156 volts for 28 seconds after starting engine. Theory of Operation: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from the O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be low, approximately 0.1 volt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor > Page 550 Possible Causes: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure - Powertrain control module failure - Connector terminals - Connector wires to sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, ASD relay, generator, and the upstream and downstream heated oxygen sensors. The PCM controls the ground circuit for each of the components powered by circuit A142. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information > Page 553 Oxygen Sensor: Testing and Inspection Oxygen Sensor Heater Circuit Test NOTE: Use an ohmmeter to test the heating element of the oxygen sensors. 1. Disconnect the electrical connector from each oxygen sensor. - The white wires in the sensor connector are the power and ground circuits for the heater elements. 2. Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. - Replace the heated oxygen sensor if the resistance is not between 4 and 7 ohms. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor Oxygen Sensor: Service and Repair Downstream O2 Sensor Fig. 19 Downstream Heated Oxygen Sensor NOTE: The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic convertor (Fig. 19). REMOVAL 1. Raise vehicle. 2. Disconnect electrical connector from sensor. 3. Disconnect sensor electrical harness from clips along body. Fig. 20 Downstream Heated Oxygen Sensor Removal/Installation 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 20). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 556 Oxygen Sensor: Service and Repair Upstream O2 Sensor Fig. 18 Upstream Heated Oxygen Sensor Removal/Installation REMOVAL 1. Raise and support vehicle. 2. Unplug sensor connector. 3. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 18). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 557 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 562 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 563 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 564 Power Steering Pressure Switch: Description and Operation Fig. 15 Power Steering Pressure Switch PURPOSE On vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. The pressure switch improves vehicle idle quality, by controlling engine idle speed when required. The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed is increased. This increase in engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The power steering pressure switch is mounted directly to the power steering gear on vehicles requiring its usage. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z12 provides ground for the power steering pressure switch. The grounding point for circuit Z12 is the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 565 Power Steering Pressure Switch: Testing and Inspection Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: Customer Interest Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 574 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: All Technical Service Bulletins Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 580 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 050596 > May > 96 > Rear Brakes - Cyclic Chirping Noise Wheel Cylinder: All Technical Service Bulletins Rear Brakes - Cyclic Chirping Noise NO: 05-05-96 GROUP: Brakes DATE: May 5, 1996 SUBJECT: Rear Brake Cyclic Chirp NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-04-96 DATED MARCH 8, 1996 AND TECHNICAL SERVICE BULLETIN 05-06-95 DATED MAY 19, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE 1996 SEBRING CONVERTIBLE HAS BEEN ADDED AND THE "PROTECT -A- CUP", LUBE IS NOW AVAILABLE THRU MOPAR PARTS. ALL CHANGES ARE MARKED WITH **ASTERISKS** MODELS: 1995 - 1996 (PL) Neon 1996 (JX) Sebring Convertible** SYMPTOM/CONDITION: A cyclic chirp noise from the rear of the vehicle during medium to light brake application, at low speeds (20 mph or less) on vehicles equipped with rear drum brakes. The noise can be related to the speed at which the tire turns (one squeak/squawk per revolution of the tire). As the vehicle slows, during the brake application, the noise will occur at a slower rate. **NOTE: THIS REPAIR HAS NO EFFECT ON THE REAR BRAKE HOWL NOISE THAT MAY OCCUR ON NEONS, AT THE END OF THE STOP. THE REAR BRAKE HOWL NOISE IS COVERED IN A SEPARATE TECHNICAL SERVICE BULLETIN.** PARTS REQUIRED: 1 4883068 "Protect -A- Cup" (Lube Cap) REPAIR PROCEDURE: This bulletin involves the installation of 4 drops of the "Protect -A- Cup" lubricant into each rear wheel cylinder. 1. Raise car on suitable hoist and remove rear wheels. 2. Remove rear brake drum retaining clips (1 per side) and remove rear brake drums. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 050596 > May > 96 > Rear Brakes - Cyclic Chirping Noise > Page 586 3. Peel back the top edge of the wheel cylinder boot and put four drops of the "Protect - A - Cup" fluid into the wheel cylinder. This fluid acts as a lubricant between the wheel cylinder the piston and the wheel cylinder boot (Figure 1). 4. Install the wheel cylinder boot onto the wheel cylinder casting. Make sure that the boot seats properly on the casting lip all the way around the wheel cylinder. 5. Repeat the process for the other three boots (two per brake). CAUTION: THE "PROTECT -A- CUP" ASSEMBLY FLUID USED TO ADDRESS THE CYCLIC CHIRP NOISE SHOULD NOT BE USED FOR ANY PURPOSE IN THE VEHICLE1S BRAKE SYSTEM OTHER THAN AS DESCRIBED IN THIS TSB. 6. Wipe any spilled fluid from the outside of the wheel cylinder as well as any other brake parts including the linings. 7. Install the brake drums, retaining clips and rear wheels. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-90-50-93 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 050596 > May > 96 > Rear Brakes - Cyclic Chirping Noise > Page 592 3. Peel back the top edge of the wheel cylinder boot and put four drops of the "Protect - A - Cup" fluid into the wheel cylinder. This fluid acts as a lubricant between the wheel cylinder the piston and the wheel cylinder boot (Figure 1). 4. Install the wheel cylinder boot onto the wheel cylinder casting. Make sure that the boot seats properly on the casting lip all the way around the wheel cylinder. 5. Repeat the process for the other three boots (two per brake). CAUTION: THE "PROTECT -A- CUP" ASSEMBLY FLUID USED TO ADDRESS THE CYCLIC CHIRP NOISE SHOULD NOT BE USED FOR ANY PURPOSE IN THE VEHICLE1S BRAKE SYSTEM OTHER THAN AS DESCRIBED IN THIS TSB. 6. Wipe any spilled fluid from the outside of the wheel cylinder as well as any other brake parts including the linings. 7. Install the brake drums, retaining clips and rear wheels. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-90-50-93 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 595 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 596 Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 597 Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS mounts to the throttle body and connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- from 0.38 to 1.03 volts. - AT Wide open throttle -- 3.1 to 4.0 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). CIRCUIT OPERATION From the Powertrain Control Module (PCM) circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 600 Throttle Position Sensor: Description and Operation Related Trouble Codes & Set Conditions Throttle Position Sensor Voltage High Name of Code: Throttle Position Sensor Voltage High When Monitored: With the ignition on. Set Condition: TP sensor voltage at PCM cavity 35 goes above 4.5 volts for 0.704 seconds. Theory of Operation: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 35. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. Possible Causes: - Sensor signal circuit open - Throttle position sensor failure - Sensor ground circuit open - PCM failure - Connector terminals - Connector wires Throttle Position Sensor Voltage Low NAME OF CODE: Throttle Position Sensor Voltage Low WHEN MONITORED: With the ignition ON. SET CONDITION: The Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 35 goes below 0.2 volt for 0.704 seconds, or MPH is above 20, RPM is above 1500, and vacuum is below 2" with TP sensor voltage less than 0.5 volt for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Throttle position sensor failure - Loss of 5-volt supply TPS Voltage Does Not Agree With MAP Name of Code: TPS Voltage Does Not Agree with MAP When Monitored: With the engine running and no MAP sensor or TP sensor trouble codes. Set Condition: The powertrain control module (PCM) performs two separate tests on the TP sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 mph and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 4 continuous seconds. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 601 Theory of Operation: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from the PCM. The sensor ground is provided by the PCM. Possible Causes: - Failed powertrain control module - Connector wires - TP sensor failure - Vehicle speed - Mechanical failure - MAP sensor - Connector terminals Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 604 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor around terminal. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately 0.38 volts to 1.03 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.0 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 605 Throttle Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 606 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 607 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (20 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Throttle Position Sensor Mounting Screws 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 611 Transmission Connections Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 614 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 615 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 616 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 617 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 618 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 619 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 620 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 621 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 622 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 623 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 624 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 625 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 626 Transmission Position Switch/Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 627 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 628 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 629 Rear Lighting (Part 1 Of 3) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Park/Neutral Position Switch Operation Transmission Position Switch/Sensor: Description and Operation Park/Neutral Position Switch Operation Fig. 20 Park/Neutral Switch OPERATION The park/neutral position switch is located on the automatic transaxle housing Fig. 20. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. CIRCUIT OPERATION When CLOSED the Transmission Range Switch (TRS) provides an input to the Powertrain Control Module (PCM) on circuit T41. This circuit connects to cavity 76 of the PCM connector. The T41 circuit is spliced and provides a ground path for the engine starter relay, and the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Park/Neutral Position Switch Operation > Page 632 Transmission Position Switch/Sensor: Description and Operation Park/Neutral Switch Failure Trouble Code Name of Code: Park/Neutral Switch Failure (Sense Circuit) When Monitored: With the transmission in Park, Neutral, or Drive and not in limp-in mode. Set Condition: This code is set if the PCM detects an incorrect Park/Neutral switch state for a given mode of vehicle operation. Theory of Operation: The Transmission range Sensor (Park/Neutral position switch on 3 speed auto and all manual trans) is used to communicate whether or not the transmission is in Park or Neutral to the PCM. When the transmission is in Park or Neutral the Park/Neutral position switch sense circuit is grounded. Possible Causes: - Connector terminals and/or wires - Park/Neutral switch failure - Mechanical transmission problem - PCM failure Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Page 633 Transmission Position Switch/Sensor: Testing and Inspection Park/Neutral Starting and Back-Up Lamp Switch 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 the switch, remove the wiring connector from the switch and test for continuity between the center pin of the switch and the transaxle case. Continuity should exist only when the transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 1. To test the switch, remove the wiring connector from the switch and test for continuity between the two outside pins. Continuity should only exist with the transaxle in the REVERSE position. 2. No continuity should exist from either pin to the transaxle case. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Page 634 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Starting and Back-Up Lamp Switch Removal 1. Place a suitable container under the switch to catch fluid when switch is removed. 2. Unscrew switch from transaxle case allowing fluid to drain into container. 3. Move selector lever to PARK, then NEUTRAL position and inspect to see the switch operating lever fingers are centered in the switch opening. Installation 1. Crew the switch with a new seal into the transaxle case and tighten to 33 Nm (24 ft. lbs.). 2. Test switch with a test lamp. 3. Add fluid to transaxle to bring up to proper level. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Mounting Bolt 2.2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 638 Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 641 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 642 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 643 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 644 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 645 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 646 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 647 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 648 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 649 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 650 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 651 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 652 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 653 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 654 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 655 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 656 Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > No Vehicle Speed Sensor Signal Trouble Code Vehicle Speed Sensor: Description and Operation No Vehicle Speed Sensor Signal Trouble Code With Electronic Automatic Transaxle NAME OF CODE: No Vehicle Speed Sensor Signal WHEN MONITORED: With engine running more than 31 seconds, engine temperature greater than 120°F, transmission not in park or neutral, brakes not applied, engine RPM greater than 1800, and MAP vacuum less than 11". SET CONDITION: No signal from the vehicle speed sensor (VSS) for more than 11 seconds. THEORY OF OPERATION: The vehicle speed sensor signal is provided to the PCM by the TCM. The signal is calculated by the TCM based on the output speed sensor signal and the speedometer pinion factor. The PCM supplies a 5 volt pull up voltage from cavity 66 to TCM cavity 58. The sensor signal is created by the TCM alternating the signal from 5V to 0.3V. POSSIBLE CAUSES: - Open or shorted signal circuit - Speedometer pinion factor not programmed - Open vehicle speed sensor circuit - PCM failure - TCM failure Without Electronic Automatic Transaxle Name of Code: No Vehicle Speed Sensor Signal When Monitored: With engine running more than 31 seconds, engine temperature greater than 180°F, transmission not in park or neutral, brakes not applied, engine rpm greater than 1,800, and MAP vacuum less than 11". Set Condition: No signal from the vehicle speed sensor for more than 11 seconds. Theory of Operation: The vehicle speed sensor is a hall-effect type sensor used to detect the transmission output shaft speed. The PCM calculates the vehicle speed based on the VSS signal. The PCM supplies 8 volts to power up the sensor. Sensor ground is supplied by the PCM. The PCM also supplies a 5.0 volt pull up voltage to the sensor. The VSS signal is created when the sensor alternates the 5.0 volt pull up from high to low. Possible Causes: - Open or shorted signal circuit - Speedometer pinion damaged - Open 5-volt supply circuit - Open sensor ground circuit - Failed vehicle speed sensor - PCM failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > No Vehicle Speed Sensor Signal Trouble Code > Page 659 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor-PCM Input Fig. 17 Vehicle Speed Sensor -- Automatic Transmission Fig. 18 Vehicle Speed Sensor -- Manual Transmission PURPOSE The sensor input is used by the PCM to determine vehicle speed and distance traveled. OPERATION The vehicle speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. Under deceleration conditions, the PCM adjusts the Idle Air Control (IAC) motor to maintain a desired MAP value. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. The vehicle speed sensor signal is also used to operate: Speedometer - Speed control - Daytime Running Lights (Canadian Vehicles only). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the Vehicle Speed Sensor (VSS). The K7 circuit connects to cavity 44 of the PCM connector. Circuit G7 from the VSS provides an input signal to the PCM. The G7 circuit connects to cavity 66 of the PCM connector. The PCM provides ground for the VSS signal (circuit G7) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Helpful Information Vehicle Speed Sensor: Testing and Inspection Helpful Information Circuit G7 splices to the speedometer and odometer in the instrument cluster. Circuit K7 splices to supply 8 Volts to the camshaft position sensor and crankshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Helpful Information > Page 662 Vehicle Speed Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 663 Vehicle Speed Sensor: Service and Repair Fig. 24 Vehicle Speed Sensor Fig. 7 Vehicle Speed Sensor And Connector Fig. 8 Vehicle Speed Sensor And Speedometer Pinion Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 664 NOTE: The vehicle speed sensor is located in the transmission extension housing (Fig. 24). REMOVAL 1. Disconnect electrical connector from sensor. 2. Remove the sensor mounting bolt. 3. Lift the sensor out of the transaxle extension housing. Ensure the 0-ring was removed with the sensor. NOTE: The speed sensor gear meshes with a gear on the output shaft. INSTALLATION 1. With 0-ring in place, install sensor and seat sensor by hand -- to ensure proper gear engagement. 2. Install mounting bolt and torque bolt to 2.2 Nm (20 in lb). 3. Connect electrical connector to sensor. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: Customer Interest Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 674 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: All Technical Service Bulletins Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 680 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 683 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 684 Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 685 Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS mounts to the throttle body and connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- from 0.38 to 1.03 volts. - AT Wide open throttle -- 3.1 to 4.0 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). CIRCUIT OPERATION From the Powertrain Control Module (PCM) circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 688 Throttle Position Sensor: Description and Operation Related Trouble Codes & Set Conditions Throttle Position Sensor Voltage High Name of Code: Throttle Position Sensor Voltage High When Monitored: With the ignition on. Set Condition: TP sensor voltage at PCM cavity 35 goes above 4.5 volts for 0.704 seconds. Theory of Operation: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 35. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. Possible Causes: - Sensor signal circuit open - Throttle position sensor failure - Sensor ground circuit open - PCM failure - Connector terminals - Connector wires Throttle Position Sensor Voltage Low NAME OF CODE: Throttle Position Sensor Voltage Low WHEN MONITORED: With the ignition ON. SET CONDITION: The Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 35 goes below 0.2 volt for 0.704 seconds, or MPH is above 20, RPM is above 1500, and vacuum is below 2" with TP sensor voltage less than 0.5 volt for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Throttle position sensor failure - Loss of 5-volt supply TPS Voltage Does Not Agree With MAP Name of Code: TPS Voltage Does Not Agree with MAP When Monitored: With the engine running and no MAP sensor or TP sensor trouble codes. Set Condition: The powertrain control module (PCM) performs two separate tests on the TP sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 mph and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 4 continuous seconds. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 689 Theory of Operation: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from the PCM. The sensor ground is provided by the PCM. Possible Causes: - Failed powertrain control module - Connector wires - TP sensor failure - Vehicle speed - Mechanical failure - MAP sensor - Connector terminals Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 692 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor around terminal. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately 0.38 volts to 1.03 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.0 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 693 Throttle Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 694 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 695 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (20 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 703 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 704 Camshaft Position Sensor: Locations Camshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 705 Camshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Operation Fig.9 Camshaft Position Sensor-DOHC PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity OPERATION Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 708 The camshaft position sensor attaches to the rear of the cylinder head (Fig. 9). 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 (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. The sensor also acts as a thrust plate to control camshaft endplay. CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the camshaft position sensor The K7 circuit connects to cavity 44 of the PCM connector. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 33 of the PCM connector. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 709 Camshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP Trouble Code Name of Code: Intermittent Loss of CMP or CKP When Monitored: During engine running. Set Condition: When the expected cam signal level disagrees with the actual cam signal level. Theory of Operation: After the engine has been started, the powertrain control module maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. Possible INTERMITTENT Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 710 Camshaft Position Sensor: Description and Operation No Cam Signal at PCM Trouble Code Name of Code: No Cam Signal at PCM When Monitored: During engine cranking, after a number of crank position sensor signals have been detected. Set Condition: Signals are not received from the camshaft position sensor when signals are received from the crankshaft position sensor Theory of Operation: The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. The PCM supplies 8 volts and a sensor ground to the CMP sensor. The camshaft position sensor signal circuit has a 5 volt pull-up from the PCM. The sensor signal is created by a rotating target magnet attached to the rear of the camshaft when the north pole of the magnet passes under the sensor, the signal remains at 5 volts. When the south pole passes under the sensor, the signal drops to 0.3 volt. Possible Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and target magnet - Damaged target magnet - Failed sensor - Failed PCM - Broken timing belt - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 713 Camshaft Position Sensor: Testing and Inspection Failure to Start Test This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 714 Camshaft Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Sensor Replacement Fig. 8 Camshaft Position Sensor Location Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head (Fig. 8). REMOVAL 1. Remove filtered air tube from the throttle body and air cleaner housing. 2. Disconnect electrical connector from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.35 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft (Fig. 35). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 717 Fig.36 Target Magnet Installation NOTE: The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft (Fig. 36). INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install filtered air tube. Tighten clamps to 3 Nm ±1 (25 in lb ±5) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 718 Camshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 723 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position Sensor Bolts ........................................................................................................ .......................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 724 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 725 Crankshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor-PCM Input Fig. 15 Crankshaft Position Sensor Fig. 14 Timing Reference Notches Fig.6 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60° signature notch (Fig. 14). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 728 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. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69° before top dead center (BTDC). - The second notch represents 49° BTDC. - The third notch represents 29°. - The last notch in each set represents 9° before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM connector. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 729 Crankshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP Trouble Code Name of Code: Intermittent Loss of CMP or CKP When Monitored: During engine running. Set Condition: When the expected cam signal level disagrees with the actual cam signal level. Theory of Operation: After the engine has been started, the powertrain control module maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. Possible INTERMITTENT Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 730 Crankshaft Position Sensor: Description and Operation No Crank Reference Signal at PCM Trouble Code Name of Code: No Crank Reference Signal at PCM When Monitored: During engine cranking, with battery voltage less than 11.5 volts and manifold vacuum present. Set Condition: No signal from the crankshaft position (CKP) sensor during engine cranking or there is a camshaft position sensor signal without a CKP sensor signal. Theory of Operation: The crankshaft position sensor is a hall-effect type sensor used to detect crankshaft speed and position. The PCM supplies 8 volts and a sensor ground to the CKP sensor. The crankshaft position sensor signal circuit has a 5-volt pull-up from the PCM. The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. When there isn't a notch under the sensor, the signal drops to 0.3 volt. Possible Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and crankshaft pulse ring - Damaged crankshaft pulse ring - Failed sensor - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 733 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 734 Crankshaft Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig. 12 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 12). 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Crankshaft Position Sensor Bolts torque ....................................................................................................................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 737 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation Fig.16 Ignition Lock Cylinder Detents The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detents: Accessory - Off (lock) - Unlock - On/Run - Start Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 742 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Detentes The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detentes: Accessory - Off (lock) - Unlock - On/Run - Start REMOVAL 1. Disconnect negative cable from battery. 2. Place key cylinder in RUN position. - Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. - Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. - To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. - Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Connect negative cable to battery Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 746 Knock Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 747 Knock Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation Knock Sensor: Description and Operation Knock Sensor Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 24 of the PCM connector. The PCM provides ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation > Page 750 Knock Sensor: Description and Operation Knock Sensor Circuit Trouble Code Name of Code: Knock Sensor Circuit When Monitored: With the ignition on and the engine running. Set Condition: The knock sensor circuit voltage falls below a minimum value at idle or deceleration, The minimum value is from a look-up table internal to the PCM and is based on engine rpm. The trouble code also sets if the sensor output is above 5.0 volts. Theory of Operation: The knock sensor is mounted on the cylinder block below the intake manifold. The knock sensor is comprised of thin piezo-electric ceramic discs bonded to a metal diaphragm. When engine knock occurs, the diaphragm vibrates along with the piezoelectric discs, producing an electrical signal. The signal is used by the PCM to adjust ignition timing to eliminate the knock condition. Possible Causes: - Sensor signal open - Sensor internally open - PCM failure - Sensor signal circuit shorted to ground - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Helpful Information Knock Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 753 Knock Sensor: Testing and Inspection Component Testing The knock sensor can be tested with a digital voltmeter. Sensor output should be between 80 mV and 4 volts with the engine running between 576 and 2,208 rpm. If the output falls outside of this range a DTC will be set. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 754 Knock Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Page 755 Knock Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 761 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 762 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 763 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 764 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 765 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 766 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 767 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 768 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 769 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 770 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 771 PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 772 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 773 POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Drivers Side Impact Sensor: Locations Drivers Side Driver Air Bag Module, Data Link Connector And Impact Sensor Locations Fig. 10 Impact Sensor Location Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Drivers Side > Page 778 Impact Sensor: Locations Passengers Side Passenger Air Bag Module And Impact Sensor Locations Fig. 10 Impact Sensor Location Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 779 Impact Sensor: Diagrams Left Impact Sensor Right Impact Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor Circuit Operation Impact Sensor: Description and Operation Impact Sensor Circuit Operation CIRCUIT OPERATION Two airbag impact sensors provide input to the Airbag Control Module (ACM). Each sensor has two circuits that connect to the ACM. From the left impact sensor, Circuit R47 connects to the ACM at cavity 2 of the 13-way connector. Circuit R49 connects to cavity 1 of the 13-way connector. From the right impact sensor, Circuit R46 connects to the ACM at cavity 12 of the 13-way connection Circuit R48 connects to cavity 13 of the 13-way connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor Circuit Operation > Page 782 Impact Sensor: Description and Operation Impact Sensor Operation FRONT IMPACT SENSORS The Driver/Passenger Airbag System is a supplemental safety device designed to help protect the driver/passenger from serious injury, caused by a frontal impact of the vehicle. The two front impact sensors provide verification of the direction and severity of the impact. The sensors are mounted on the left and right side of the radiator closure panel under the vehicle's hood. The impact sensors are threshold sensitive switches that complete an electrical circuit when an impact provides a sufficient acceleration to close the switch. The sensors are calibrated for the specific vehicle and react to the severity and direction of the impact. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor Impact Sensor: Service and Repair Left Impact Sensor Fig. 7 Remove Or Install Battery Cable WARNING: Before beginning any airbag system component removal or installation procedures, disconnect and isolate the battery negative (ground) cable. This will disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. 1. Remove battery negative cable and battery positive cable in this order. 2. Remove battery thermoguard. 3. Remove battery hold down clamp and battery from vehicle. 4. Remove battery tray and air inlet hose. Fig. 10 Impact Sensor Location 5. Remove sensor and disconnect impact sensor electrical connector. Fig. 11 Impact Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor > Page 785 6. For installation, reverse above procedures. Install sensor (arrow pointed forward as shown, to the stud plate on the closure panel, using three nuts provided with new sensor and tighten to 6 Nm (50 in lb) torque. Do not connect battery negative cable. Refer to Airbag System Check for proper procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor > Page 786 Impact Sensor: Service and Repair Right Impact Sensor Fig. 7 Remove Or Install Battery Cable WARNING: Before beginning any airbag system component removal or installation procedures, disconnect and isolate the battery negative (ground) cable. This will disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. 1. Remove battery negative cable and battery positive cable in this order. 2. Remove radiator fan module. 3. Drain and remove radiator. Fig. 10 Impact Sensor Location 4. Remove three nuts holding sensor to stud plate on the closure panel. 5. Remove sensor and disconnect impact sensor electrical connector. Fig. 11 Impact Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor > Page 787 6. For installation, reverse above procedures. Install sensor (arrow pointed forward as shown, to the stud plate on the closure panel, using three nuts provided with new sensor and tighten to 6 Nm (50 in lb) torque. Do not connect battery negative cable. Refer to Airbag System Check for proper procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Battery Temp Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 792 Battery Temp Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 793 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation > General Description Battery Temperature Sensor: Description and Operation General Description CIRCUIT OPERATION From circuit G31 the battery temperature sensor draws voltage from the Powertrain Control Module (PCM). The sensor is a variable resistor. As battery temperature changes, the resistance in the sensor changes causing a change in current draw. Circuit G31 connects to cavity 52 of the PCM connector. The PCM provides ground for the battery temperature sensor signal (circuit G31) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation > General Description > Page 796 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor Operation Sensor External to the PCM Name of Code: Battery Temp Sensor (BTS) Voltage Either Too High or Too Low When Monitored: With the ignition key on. Set Condition: The PCM senses the voltage from the BTS to be either below 0.5 volts or above 4.9 volts for 3 seconds. Theory of Operation: The battery temp sensor voltage is used by the PCM to determine what the charging system goal should be. The PCM uses that goal to determine the charging output level. The battery temp sensor is external to the PCM. Possible Causes: - Battery temp sensor failure - Open circuit in battery temp sensor signal circuit - Short circuit in battery temp sensor signal circuit - PCM failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Battery Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Service and Repair Clutch Switch: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect electrical connector from switch. 3. Depress tabs on switch and push through mounting bracket. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation Fig.16 Ignition Lock Cylinder Detents The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detents: Accessory - Off (lock) - Unlock - On/Run - Start Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 806 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Detentes The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detentes: Accessory - Off (lock) - Unlock - On/Run - Start REMOVAL 1. Disconnect negative cable from battery. 2. Place key cylinder in RUN position. - Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. - Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. - To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. - Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Connect negative cable to battery Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Transmission Control Solenoid Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 810 Park Neutral Position Switch Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 811 Neutral Safety Switch: Description and Operation CIRCUIT OPERATION When CLOSED, the park/neutral position switch provides a ground path on circuit T41 for the coil side of the engine starter motor relay The case grounded switch provides ground for circuit T41. Circuit A41 from the ignition switch provides battery voltage to the coil side of the relay. Circuit T41 splices to cavity 76 of the Powertrain Control Module (PCM). The park/neutral position switch provides an input to the PCM. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 812 Neutral Safety Switch: Testing and Inspection In the START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) to circuit A41. A 30 Amp fuse protects circuits A1 and A41. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 819 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 820 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 821 Power Steering Pressure Switch: Description and Operation Fig. 15 Power Steering Pressure Switch PURPOSE On vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. The pressure switch improves vehicle idle quality, by controlling engine idle speed when required. The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed is increased. This increase in engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The power steering pressure switch is mounted directly to the power steering gear on vehicles requiring its usage. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z12 provides ground for the power steering pressure switch. The grounding point for circuit Z12 is the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 822 Power Steering Pressure Switch: Testing and Inspection Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Throttle Position Sensor Mounting Screws 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 828 Transmission Connections Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 831 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 832 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 833 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 834 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 835 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 836 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 837 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 838 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 839 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 840 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 841 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 842 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 843 Transmission Position Switch/Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 844 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 845 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 846 Rear Lighting (Part 1 Of 3) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Park/Neutral Position Switch Operation Transmission Position Switch/Sensor: Description and Operation Park/Neutral Position Switch Operation Fig. 20 Park/Neutral Switch OPERATION The park/neutral position switch is located on the automatic transaxle housing Fig. 20. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. CIRCUIT OPERATION When CLOSED the Transmission Range Switch (TRS) provides an input to the Powertrain Control Module (PCM) on circuit T41. This circuit connects to cavity 76 of the PCM connector. The T41 circuit is spliced and provides a ground path for the engine starter relay, and the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Park/Neutral Position Switch Operation > Page 849 Transmission Position Switch/Sensor: Description and Operation Park/Neutral Switch Failure Trouble Code Name of Code: Park/Neutral Switch Failure (Sense Circuit) When Monitored: With the transmission in Park, Neutral, or Drive and not in limp-in mode. Set Condition: This code is set if the PCM detects an incorrect Park/Neutral switch state for a given mode of vehicle operation. Theory of Operation: The Transmission range Sensor (Park/Neutral position switch on 3 speed auto and all manual trans) is used to communicate whether or not the transmission is in Park or Neutral to the PCM. When the transmission is in Park or Neutral the Park/Neutral position switch sense circuit is grounded. Possible Causes: - Connector terminals and/or wires - Park/Neutral switch failure - Mechanical transmission problem - PCM failure Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Page 850 Transmission Position Switch/Sensor: Testing and Inspection Park/Neutral Starting and Back-Up Lamp Switch 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 the switch, remove the wiring connector from the switch and test for continuity between the center pin of the switch and the transaxle case. Continuity should exist only when the transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 1. To test the switch, remove the wiring connector from the switch and test for continuity between the two outside pins. Continuity should only exist with the transaxle in the REVERSE position. 2. No continuity should exist from either pin to the transaxle case. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Page 851 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Starting and Back-Up Lamp Switch Removal 1. Place a suitable container under the switch to catch fluid when switch is removed. 2. Unscrew switch from transaxle case allowing fluid to drain into container. 3. Move selector lever to PARK, then NEUTRAL position and inspect to see the switch operating lever fingers are centered in the switch opening. Installation 1. Crew the switch with a new seal into the transaxle case and tighten to 33 Nm (24 ft. lbs.). 2. Test switch with a test lamp. 3. Add fluid to transaxle to bring up to proper level. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Master Window Switch Power Window Switch: Description and Operation Master Window Switch Left Window Operation CIRCUIT OPERATION When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q21 circuit. The Q21 circuit connects from the switch to the left front window motor Grounding is provided on circuit Q11 from the motor back to the switch. The ground is passed through the switch to the Z8 circuit. The Z8 circuit goes to its grounding point. When window UP operation is selected, the power and ground circuits are reversed. Circuit Q11 is the feed and circuit Q21 is the ground. Right Window Operation CIRCUIT OPERATION When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q26 circuit. The Q26 circuit connects from the master switch to the right window switch. A BUS bar internal to the right switch passes the voltage through the switch to circuit Q22. Circuit Q22 connects from the switch to the right window motor. Grounding is provided on circuit Q12 from the motor back to the right switch. The ground is passed through the switch on a BUS bar to circuit Q16. Circuit Q16 then goes to the master switch. The ground is passed through the switch to the Z8 circuit. The Z8 circuit attaches to its grounding point. When window UP operation is selected, the power and ground circuits are reversed. Circuits Q12 and Q16 are the feeds and circuits Q22 and Q26 are the grounds. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Master Window Switch > Page 857 Power Window Switch: Description and Operation Passenger Side Switch Operation CIRCUIT OPERATION When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q22 circuit. The Q22 circuit connects from the switch to the right front window motor Grounding is provided on circuit Q12 from the motor back to the switch. The ground is passed through the switch to the Q16 circuit. The Q16 circuit connects from the right switch to the master switch. Ground is passed through the master switch to the Z8 circuit. The Z8 circuit goes to its grounding point. When window UP operation is selected, the power and ground circuits are reversed. Circuit Q12 is the feed and circuit Q22 is the ground. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Page 858 Power Window Switch: Testing and Inspection - Check the 40 Amp fuse located in the PDC. - Check the 30 Amp circuit breaker located behind the fuse block. - Check the ground at the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection Wiper Switch: Testing and Inspection Fig.9 Wiper Switch Tests 1. Disconnect wiper switch wiring from main wiring at steering column. 2. Using a suitable ohmmeter test continuity between connector pins as shown. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 863 Wiper Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove three screws from steering column shroud and remove upper half of shroud. 3. Remove mounting screws on switch and remove switch. 4. Disconnect electrical connector from switch. 5. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration Alignment: Customer Interest Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 873 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 874 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration Alignment: All Technical Service Bulletins Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 880 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 881 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment Alignment: All Technical Service Bulletins Alignment & Suspension - Specifications & Adjustment NO: 02-04-97 GROUP: Suspension DATE: May 16, 1997 SUBJECT: Front End Alignment Torque Specifications & Shock Adjustment Procedures On Competition Package MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH THE COMPETITION PACKAGE SALES CODE (ACR) SUSPENSION SALES CODE (SDK). DISCUSSION: The alignment on ACR equipped vehicles must be set to the preferred specifications provided in the 1997 Neon Service Manual (Publication Number 81-270-7025) page 2-7. After each final setting the nuts should then be torqued to 75 ft.lbs plus an additional 90 degree turn. It is important that the proper torque be used to maintain the proper alignment. If the alignment is outside of specifications, rapid and excessive tire wear will result. Starting in 1997, Neon competition package (ACR) vehicles come equipped with adjustable strut dampers on all four wheels. The struts are finely tuned to the ride and handling profile of the entire suspension system. If the customer wishes to change the dampening force for special conditions the dampening characteristics of the strut dampers are adjustable on the ACR equipped vehicles. The knob for adjusting the strut can be found in a packet located in the glove compartment. The adjustment procedures are as follows: 1. The top end of the adjusting rod has flats over which the adjusting knob will fit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment > Page 886 2. Install the knob over the top end of the front or rear damper and lock it into position by turning counterclockwise slowly until the knob engages, (Illustration). 3. Turn the adjusting knob clockwise, if resistance is felt do not use force, as the damper is in an unadjusted position. Reverse the adjustment slightly and try again. When the damper is in the full clockwise position, this is the minimum (City Ride) position. 4. To adjust the dampening force, the adjusting knobs has to be turned in the direction of the arrow for increased dampening and the opposite direction for decreased dampening. NOTE: BOTH THE LEFT AND RIGHT STRUT DAMPERS MUST BE ADJUSTED IDENTICALLY. FAILURE TO DO SO COULD PRODUCE UNSTABLE HANDLING AND UNEVEN TIRE TREAD WEAR. 5. The following is a description of the various settings and the adjustment procedure. A. City Ride - To enjoy the most comfortable city ride, the struts should be left in the "minimum" position as they are set from the assembly plant. To set to minimum the knob should be turned completely clockwise. B. Cross Country - The cross country setting will give the car a firmer handling characteristic, but yet will still be very comfortable to drive. To set, turn the adjusting knob 1/2 turn counter clockwise from the "minimum" position. C. G.T./Aggressive Driving - This setting equates the car's handling to a cross-country grand turismo car, offering increased cornering ability, improved road feel and precise directional stability at higher speeds. To set turn the adjusting knob 1 turn counter clockwise from the "minimum" position. 6. Remove the adjusting knob before closing the hood or trunk. The vehicle should not be driven with the adjusting knob in place. NOTE: DURING INSPECTION/SERVICING A THIN FILM OF OIL AND DUST COLLECTION MAY BE NOTICED ON THE OUTSIDE OF THE STRUT TUBE. THIS IS A NORMAL CONDITION WHICH OCCURS DURING THE DAMPER INTERNAL SEAL "BREAK-IN" PERIOD AND DOES NOT AFFECT THE PERFORMANCE OF THE STRUT AND DOES NOT INDICATE THE NEED FOR STRUT REPLACEMENT. STRUT REPLACEMENT SHOULD ONLY OCCUR IF THE STRUT LEAKAGE IS SUFFICIENT TO COVER THE ENTIRE STRUT DAMPER TUBE AND HAS "DRIPPED" ONTO THE LOWER CONTROL ARM OR ONTO THE PAVEMENT DURING OVERNIGHT PARKING. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 26-12-96G > Dec > 96 > Steering/Suspension - Alignment Specifications Revisions Alignment: All Technical Service Bulletins Steering/Suspension - Alignment Specifications Revisions NUMBER: 26-12-96G GROUP: Miscellaneous DATE: December, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1996 Neon - Publication Number 81-270-6025 DESCRIPTION OF CHANGES Revision the front end alignment specifications Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 26-12-96G > Dec > 96 > Steering/Suspension - Alignment Specifications Revisions > Page 891 2-7 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment Alignment: All Technical Service Bulletins Alignment & Suspension - Specifications & Adjustment NO: 02-04-97 GROUP: Suspension DATE: May 16, 1997 SUBJECT: Front End Alignment Torque Specifications & Shock Adjustment Procedures On Competition Package MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH THE COMPETITION PACKAGE SALES CODE (ACR) SUSPENSION SALES CODE (SDK). DISCUSSION: The alignment on ACR equipped vehicles must be set to the preferred specifications provided in the 1997 Neon Service Manual (Publication Number 81-270-7025) page 2-7. After each final setting the nuts should then be torqued to 75 ft.lbs plus an additional 90 degree turn. It is important that the proper torque be used to maintain the proper alignment. If the alignment is outside of specifications, rapid and excessive tire wear will result. Starting in 1997, Neon competition package (ACR) vehicles come equipped with adjustable strut dampers on all four wheels. The struts are finely tuned to the ride and handling profile of the entire suspension system. If the customer wishes to change the dampening force for special conditions the dampening characteristics of the strut dampers are adjustable on the ACR equipped vehicles. The knob for adjusting the strut can be found in a packet located in the glove compartment. The adjustment procedures are as follows: 1. The top end of the adjusting rod has flats over which the adjusting knob will fit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment > Page 897 2. Install the knob over the top end of the front or rear damper and lock it into position by turning counterclockwise slowly until the knob engages, (Illustration). 3. Turn the adjusting knob clockwise, if resistance is felt do not use force, as the damper is in an unadjusted position. Reverse the adjustment slightly and try again. When the damper is in the full clockwise position, this is the minimum (City Ride) position. 4. To adjust the dampening force, the adjusting knobs has to be turned in the direction of the arrow for increased dampening and the opposite direction for decreased dampening. NOTE: BOTH THE LEFT AND RIGHT STRUT DAMPERS MUST BE ADJUSTED IDENTICALLY. FAILURE TO DO SO COULD PRODUCE UNSTABLE HANDLING AND UNEVEN TIRE TREAD WEAR. 5. The following is a description of the various settings and the adjustment procedure. A. City Ride - To enjoy the most comfortable city ride, the struts should be left in the "minimum" position as they are set from the assembly plant. To set to minimum the knob should be turned completely clockwise. B. Cross Country - The cross country setting will give the car a firmer handling characteristic, but yet will still be very comfortable to drive. To set, turn the adjusting knob 1/2 turn counter clockwise from the "minimum" position. C. G.T./Aggressive Driving - This setting equates the car's handling to a cross-country grand turismo car, offering increased cornering ability, improved road feel and precise directional stability at higher speeds. To set turn the adjusting knob 1 turn counter clockwise from the "minimum" position. 6. Remove the adjusting knob before closing the hood or trunk. The vehicle should not be driven with the adjusting knob in place. NOTE: DURING INSPECTION/SERVICING A THIN FILM OF OIL AND DUST COLLECTION MAY BE NOTICED ON THE OUTSIDE OF THE STRUT TUBE. THIS IS A NORMAL CONDITION WHICH OCCURS DURING THE DAMPER INTERNAL SEAL "BREAK-IN" PERIOD AND DOES NOT AFFECT THE PERFORMANCE OF THE STRUT AND DOES NOT INDICATE THE NEED FOR STRUT REPLACEMENT. STRUT REPLACEMENT SHOULD ONLY OCCUR IF THE STRUT LEAKAGE IS SUFFICIENT TO COVER THE ENTIRE STRUT DAMPER TUBE AND HAS "DRIPPED" ONTO THE LOWER CONTROL ARM OR ONTO THE PAVEMENT DURING OVERNIGHT PARKING. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 26-12-96G > Dec > 96 > Steering/Suspension - Alignment Specifications Revisions Alignment: All Technical Service Bulletins Steering/Suspension - Alignment Specifications Revisions NUMBER: 26-12-96G GROUP: Miscellaneous DATE: December, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1996 Neon - Publication Number 81-270-6025 DESCRIPTION OF CHANGES Revision the front end alignment specifications Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 26-12-96G > Dec > 96 > Steering/Suspension - Alignment Specifications Revisions > Page 902 2-7 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 903 Alignment: By Symptom Technical Service Bulletin # 02-09-99 Date: 990702 Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 904 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 905 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Technical Service Bulletin # 02-09-99 Date: 990702 Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 906 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 907 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 908 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 909 Alignment: Specifications The content of this article reflects changes called for in TSB 26-12-96. NOTE: All alignment specifications are taken at curb height. FRONT: Camber: Acceptable Range ................................................................................................................ ........................................................................ -0.4° to +0.4° Preferred Setting .................................. .............................................................................................................................................................. .......... 0.0° S/C ACR only [3] ............................................................................................................... .......................................................................... -2.4° to +0.4° Total Toe [1]: Acceptable Range ......................................................................................................... ........................................................................ 0.3° in to 0.1° out Preferred Setting ............................ .............................................................................................................................................................. ............ 0.1° in S/C ACR only [3] ......................................................................................................... ................................................................... 0.30° In to 0.70° Out Caster*: Acceptable Range ................................................................................................................. ....................................................................... +1.8° to +3.8° Preferred Setting .................................. .............................................................................................................................................................. ........ +2.8° * Side To Side Caster: Not To Exceed ................................................................................................ ................................................................................................. 1.0° or less REAR: Camber: Acceptable Range ................................................................................................................ .................................................................... -0.75° to +0.25° Preferred Setting .................................. .............................................................................................................................................................. ....... -0.25° S/C ACR only [3] ............................................................................................................... ...................................................................... -1.00° to +0.25° Total Toe [1] [2]: Acceptable Range .................................................................................................... .............................................................................. 0.3° in to 0.1°out Preferred Setting ....................... .............................................................................................................................................................. ................. 0.1° in S/C ACR only [3] .................................................................................................... ........................................................................ 0.30° In to 0.50° Out Thrust Angle ........................................................................................................................................ .................................................... -0.10° to +0.10° [1]: Total toe is the arithmetic sum of the left and right wheel toe settings. Positive is toe-in, negative is toe-out. Total toe must be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Left and right toe must be equal to within 0.02 degrees. [2]: Toe-out when backed on to the alignment rack is toe in when driving. [3]: The alignment specifications shown, are only for vehicles which are equipped with the ACR (Competition Package) sales code. This specification is listed to show the adjustable range for the Camber and Toe on the front and rear suspension of a vehicle with the Competition Package. These alignment specifications are only to be used at the request of the vehicle owner and only when the vehicle is going to be used in a competition event. The alignment is to be set back to the preferred setting before the vehicle is returned to normal operation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment Alignment: Service and Repair Front Alignment Adjustment Camber & Toe Alignment Caster and camber settings are determined by the location of vehicle's suspension components. No adjustment of caster and camber is possible after vehicle is built or when servicing suspension components. Caster and camber are not normally considered an adjustable specification when performing an alignment on this vehicle. CASTER If caster is not within specifications, check for damaged suspension components or body damage causing component locations to change. NOTE: No adjustment is possible for caster. CAMBER 1. Correctly position vehicle on alignment rack and install all required equipment, per alignment equipment specifications. 2. Center steering wheel and lock in place using steering wheel clamp. 3. Jounce vehicle, then read front alignment settings and compare to specifications. 4. If camber readings obtained are not within specifications, a Mopar Service Kit will be required. 5. Raise and support vehicle, then remove original upper bolt attaching front strut clevis bracket to steering knuckle. 6. Loosen lower bolt attaching strut clevis bracket to steering knuckle only enough to allow knuckle to move in clevis bracket. 7. Install bolt from service kit into upper strut clevis bracket to steering knuckle mounting hole. 8. Install nut provided by service kit on replacement bolt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment > Page 912 9. Tighten upper bolt and nut from service kit until snug, but still allowing movement between strut clevis bracket and knuckle. 10. Remove original lower bolt and install bolt from service kit into lower strut clevis bracket hole. Install nut and tighten until snug. 11. Lower vehicle until full weight is supported by suspension, then jounce front and rear of vehicle an equal number of times. 12. Adjust camber to preferred setting by pushing or pulling top of tire. 13. Tighten upper and lower strut clevis bracket bolts. 14. Jounce vehicle an equal number of times and verify rear camber setting. When vehicle is at correct setting, torque both front strut clevis brackets to 40 ft. lbs. plus an additional 1/4 turn. TOE Rear wheel toe must be set prior to setting front wheel toe. Proceed as follows: 1. Center steering wheel and lock in place using a steering wheel clamp. Rear Lateral Link Toe Setting 2. Loosen nuts on attaching bolts for left and right lateral links to rear crossmember. Rear Wheel Toe Adjustment Cams 3. Rotate lateral link adjustment cams, until preferred rear toe specification is obtained. 4. While holding toe adjustment cams from turning, tighten right and left lateral links to rear crossmember attaching bolt nuts. This will securely hold adjustment cams in position. 5. Hold lateral link attaching bolt and adjustment cam from turning and torque lateral link attaching bolt to 70 ft.-lbs. 6. Loosen front inner tie rod end jam nuts, then grasp inner tie rods at serration. 7. Rotate inner tie rods of steering gear and set front toe specifications. 8. Torque tie rod lock nuts to 45 ft.-lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment > Page 913 Preliminary Inspection - Ensure vehicle has a full tank of gas when wheel alignment specifications are checked or adjusted. One full tank of gas is approximately 75 lbs. - If tank is not full, this change in weight will affect curb height of vehicle and alignment specifications. - Check and adjust tire pressure. Ensure all tires are the same size. - Inspect all suspension components for looseness or damage. Components showing signs of wear or damage should be replaced before alignment. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment > Page 914 Alignment: Service and Repair Rear Alignment Camber & Toe Alignment Caster and camber settings are determined by the location of vehicle's suspension components. No adjustment of caster and camber is possible after vehicle is built or when servicing suspension components. Caster and camber are not normally considered an adjustable specification when performing an alignment on this vehicle. CASTER If caster is not within specifications, check for damaged suspension components or body damage causing component locations to change. - No adjustment is possible for caster. CAMBER 1. Correctly position vehicle on alignment rack and install all required equipment, per alignment equipment specifications. 2. Jounce vehicle and read rear alignment settings and compare to specifications. 3. If camber readings obtained are not within specifications, a Mopar Service Kit will be required. 4. Raise and support vehicle, then remove original upper bolt attaching rear strut clevis bracket to rear knuckle. 5. Loosen lower bolt attaching strut clevis bracket to rear knuckle only enough to allow knuckle to move in clevis bracket. 6. Install bolt from service kit into upper strut clevis bracket to rear knuckle mounting hole. 7. Install nut provided by service kit on replacement bolt. 8. Tighten upper bolt and nut from service kit until snug, but still allowing movement between strut clevis bracket and knuckle. 9. Remove original lower bolt and install bolt from service kit into lower strut clevis bracket hole. Install nut and tighten until snug. 10. Lower vehicle until full weight is supported by suspension, then jounce front and rear of vehicle an equal number of times. 11. Adjust camber to preferred setting by pushing or pulling top of tire. 12. Tighten upper and lower strut clevis bracket bolts. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Alignment > Page 915 13. Jounce vehicle an equal number of times and verify rear camber setting. When vehicle is at correct setting, torque rear strut clevis brackets to 70 ft.-lbs. TOE Rear wheel toe must be set prior to setting front wheel toe. Proceed as follows: 1. Center steering wheel and lock in place using a steering wheel clamp. Rear Lateral Link Toe Setting 2. Loosen nuts on attaching bolts for left and right lateral links to rear crossmember. Rear Wheel Toe Adjustment Cams 3. Rotate lateral link adjustment cams until preferred rear toe specification is obtained. 4. While holding toe adjustment cams from turning, tighten right and left lateral links to rear crossmember attaching bolt nuts. This will securely hold adjustment cams in position. 5. Hold lateral link attaching bolt and adjustment cam from turning and torque lateral link attaching bolt to 70 ft.-lbs. 6. Loosen front inner tie rod end jam nuts, then grasp inner tie rods at serration. 7. Rotate inner tie rods of steering gear and set front toe specifications. 8. Torque tie rod lock nuts to 45 ft.-lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Typical -- SOHC Shown Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Curb idle speed ................................................................................................................................... .......................................................... 700 +/- 100 rpm Idle speed when A/C is ON (in neutral) .......... .......................................................................................................................................................... 850 rpm Basic idle speed .................................................................................................................... .......................................................................... 700 +/- 50 rpm NOTE: If these specs differ from the under hood label, then use the information found on the under hood label. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 924 Idle Speed: Testing and Inspection Fig. 31 PCV Vacuum Nipple 1. Turn ignition key off. 2. Disconnect the PCV valve hose from the intake manifold nipple (Fig. 31). Cap the PCV vacuum nipple. Fig. 32 Purge Hose 3. Disconnect purge hose from the nipple on the throttle body (Fig. 32). Fig. 33 Orifice 6457 Attached To Purge Nipple 4. Use a piece of hose to attach Air Metering Orifice 6457 (0.125 in. orifice) or equivalent, to the purge nipple on the throttle body (Fig. 33). 5. Ensure that all accessories are off. 6. Connect the DRB or equivalent scan tool to the data link connector inside the passenger compartment. 7. Run engine in Park or Neutral until the cooling fan has cycled on and off at least once (180°F). 8. Using the DRB or equivalent scan tool, access Minimum Airflow Idle Speed. 9. The following will then occur: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 925 - Idle air control motor will fully close - Idle spark advance will become fixed - PCM will go open loop enriched - DRB or equivalent scan tool displays engine RPM 10. If idle RPM is within the range shown below, throttle body minimum airflow is set correctly. Odometer Reading Idle RPM Below 1,000 Miles 550 - 1,300 RPM Above 1,000 Miles 600 - 1,300 RPM 11. If idle RPM is above specifications, use the DRB or equivalent scan tool to check idle air control motor operation. If idle air control motor is OK, replace throttle body. If idle air flow is below specification, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash thoroughly after using cleaner. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when is closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 14. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 12. Shut off engine. 13. Remove Air Metering Orifice 6457 or equivalent. Install purge hose. 14. Remove cap from PCV valve. Connect hose to PCV valve. 15. Remove DRB or equivalent scan tool. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad Air Cleaner Fresh Air Duct/Hose: Customer Interest Fresh Air Duct - Contacts Hood Insulator Pad NO: 14-05-96 GROUP: Fuel DATE: June 7, 1996 SUBJECT: Wear Marks On Fresh Air Duct And Hood Pad MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES BUILT WITH SPORT/EXPRESSO BUBBLE HOODS AND 2.0L SOHC ENGINES. SYMPTOM/CONDITION: Wear marks on either the fresh air duct or hood pad, due to contact between the two components may be visible. The contact between the fresh air duct and hood pad do not result in a functional problem, but the indentations may be objectional to the customer. PARTS REQUIRED: 1 4669962 Duct, Fresh Air REPAIR PROCEDURE: This bulletin involves the installation of a new fresh air duct which provides additional clearance. 1. Remove the plastic wing nut from the fresh air duct mount. See Illustration. 2. Remove the fresh air duct from the air cleaner box. 3. Install new fresh air duct (P/N 4669962) in the air cleaner box. CAUTION: THE FRESH AIR DUCT MUST BE COMPLETELY SNAPPED INTO THE AIR CLEANER BOX. VERIFY THAT THE DUCT IS FIRMLY IN PLACE. 4. Install the wing nut, while pushing down in the marked area of the fresh air duct. See Illustration. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad > Page 935 TIME ALLOWANCE: Labor Operation No: 14-10-29-92 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Fresh Air Duct - Contacts Hood Insulator Pad NO: 14-05-96 GROUP: Fuel DATE: June 7, 1996 SUBJECT: Wear Marks On Fresh Air Duct And Hood Pad MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES BUILT WITH SPORT/EXPRESSO BUBBLE HOODS AND 2.0L SOHC ENGINES. SYMPTOM/CONDITION: Wear marks on either the fresh air duct or hood pad, due to contact between the two components may be visible. The contact between the fresh air duct and hood pad do not result in a functional problem, but the indentations may be objectional to the customer. PARTS REQUIRED: 1 4669962 Duct, Fresh Air REPAIR PROCEDURE: This bulletin involves the installation of a new fresh air duct which provides additional clearance. 1. Remove the plastic wing nut from the fresh air duct mount. See Illustration. 2. Remove the fresh air duct from the air cleaner box. 3. Install new fresh air duct (P/N 4669962) in the air cleaner box. CAUTION: THE FRESH AIR DUCT MUST BE COMPLETELY SNAPPED INTO THE AIR CLEANER BOX. VERIFY THAT THE DUCT IS FIRMLY IN PLACE. 4. Install the wing nut, while pushing down in the marked area of the fresh air duct. See Illustration. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad > Page 941 TIME ALLOWANCE: Labor Operation No: 14-10-29-92 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Fig. 104 Air Intake Duct Fig. 105 Removal/Installation of Air Inlet Duct NOTE: Neon vehicles do not use a heated air inlet system. The PCM adjusts fuel injector pulse width and ignition timing to compensate for different ambient temperatures. NOTE: The air cleaner attaches to a bracket on the rear of the cylinder head. An ambient air duct supplies underhood air for the engine. REMOVAL 1. Remove air intake tube (Fig. 104) from air cleaner and intake manifold (Fig. 105). Fig. 106 Removal/Installation Air Cleaner Front Housing and Element 2. Tighten clasps on top of air cleaner housing. Rotate front of housing forward then lift front away from air cleaner housing (Fig 106). 3. Remove air cleaner element from front housing (Fig. 106). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 945 INSTALLATION 1. Install air cleaner element into front housing. 2. Rotate front of housing forward then lower into place and locate tabs in slots. - Fasten clasps on top of air cleaner housing. - Install air intake duct at air cleaner and intake manifold. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 950 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 12 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) 6. Replace Pressure test port cap when finished releasing pressure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications 1995 - 1996 2.0L, 2.4L Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Cable Routing and Firing Order Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum Cables #1 & #4 3,050 Ohms 4,250 Ohms Cables #2 & #3 2,300 Ohms 3,300 Ohms Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 961 Ignition Cable: Description and Operation NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Plastic clips in various locations protect the cables from damage. When the cables are replaced the clips must be used to prevent damage to the cables. The #1 cable must be routed under the PCV hose and clipped to the #2 cable. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Ignition Cable: Initial Inspection and Diagnostic Overview Fig. 3 Spark Plug Cables NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Be sure that the plastic clip on PCV hose is positioned so that cable clip is beneath hose, and that #1 cable is snapped into this clip to protect it from metal PCV clamp. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 964 Ignition Cable: Component Tests and General Diagnostics Testing For Open Circuits, High Resistance and Loose Terminals Use an ohmmeter to check cables for opens, loose terminals or high resistance as follows: 1. Remove cable from spark plug. 2. Remove cable from the coil tower. 3. Connect the ohmmeter between the spark plug end terminal and the coil end terminal. - Make sure ohmmeter probes are in good contact. - Resistance should be within tolerance shown in the cable resistance chart. - If resistance is not within tolerance, replace cable assembly. Test all spark plug cables in the same manner. - If no problems are found, SEE Ignition System/System Diagnosis/Testing For Spark At Coil. SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum Cables #1 & #4 3,050 Ohms 4,250 Ohms Cables #2 & #3 2,300 Ohms 3,300 Ohms Testing For Punctures and Cracks When testing cables for punctures and cracks with an oscilloscope and an inductive voltage probe, follow the instructions of the equipment manufacturers. CAUTION: Do not leave any one spark plug cable disconnected for more than 30 seconds during test or possible heat damage to catalytic converter will occur. If an oscilloscope and inductive probe are not available, cables can be tested as follows: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. WARNING: The ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. 2. With the engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). - If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. - Replace cracked, leaking or faulty cables. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning Ignition Cable: Service and Repair Cleaning Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning > Page 967 Ignition Cable: Service and Repair Replacement Fig. 3 Spark Plug Cables NOTE: The cables insulate the spark plugs and cover the top of the spark plug tube (Fig. 3). CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. REMOVAL 1. Remove spark plug cable from coil first. Lightly grasp the top of the cable. 2. Rotate the insulator 1/2 turn and pull straight up in a steady motion. 3. To replace the cables, disconnect the cable from the ignition coil. INSTALLATION Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube.Then connect the other end to coil pack. Be sure that the plastic clip on PCV hose is positioned so that cable clip is beneath hose, and that #1 cable is snapped into this clip to protect it from metal PCV clamp. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Spark Plugs - Intermittent Misfire Spark Plug: Technical Service Bulletins Spark Plugs - Intermittent Misfire NO: 18-10-97 GROUP: Vehicle Performance DATE: Feb. 28, 1997 SUBJECT: Intermittent Single Cylinder Misfire And/Or MIL Illuminated THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-15-96 REV. A DATED JULY 12, 1996 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1996 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-97010). ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE SPECIFIC ENGINE APPLICATIONS FOR FJ MODELS. MODELS: 1995 - 1996 (PL) Neon 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH 2.0L SOHC ENGINE (JA & PL), PRIOR TO JANUARY 2, 1996 (MDH 01-02-XX) AND WITH 2.0L DOHC ENGINE (PL) PRIOR TO APRIL 1, 1996 (MDH 04-01-XX) AND TO ALL 1995 & 1996 FJ **NATURALLY ASPIRATED** 2.0L VEHICLES. SYMPTOM/CONDITION: Intermittent single cylinder misfire as indicated by the Diagnostic Trouble Code (DTC) screen on the DRB III which cannot be readily reproduced. DIAGNOSIS: Follow the diagnostic steps in the 1996 Powertrain Diagnostic Manual for 2.0L/2.4L/2.5L/3.3L/3.5L Electronic Fuel Injection (Publication Number 81-699-95008), pages 417 to 419 (Test 107A). If the diagnostic repair procedure does not repair the problem, proceed to the repair procedure. PARTS REQUIRED: NOTE: IT IS IMPERATIVE THAT THE CHRYSLER PART NUMBER GIVEN BELOW BE REQUESTED WHEN ORDERING. ONLY THE CHRYSLER PART NUMBER WAS CHANGED, THE CHAMPION PART NUMBER DID NOT CHANGE. AR 5269897 Spark Plug, (PL & JA - SOHC & DOHC) AR 5269899 Spark Plug, (FJ- DOHC **Naturally Aspirated**) REPAIR PROCEDURE: This bulletin involves the replacement of the spark plug in the effected cylinder with a new spark plug. 1. Remove the spark plug cable. 2. Remove the spark plug and discard. 3. Install the new spark plug and torque to 28 Nm (20 ft. lbs.). 4. Install the spark plug cable. NOTE: THE FOLLOWING STEP IS REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Spark Plugs - Intermittent Misfire > Page 972 5. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-17-03-91 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications Spark Plug: Specifications Gap Specifications Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap .............................................................................................................................................. ............................................. 0.033 to 0.038 in Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications > Page 975 Spark Plug: Specifications Tightening Specifications Spark Plugs ......................................................................................................................................... ................................................ 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications > Page 976 Spark Plug: Specifications Part Number and Thread Size Type - Champion RC9YC Thread size - 14mm (3/4 in) reach Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 977 Spark Plug: Application and ID Type - Champion RC9YC Thread size - 14mm (3/4 in) reach Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 978 Spark Plug: Description and Operation Resistor spark plugs are used in this engine. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for spark plug diagnosis. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 981 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 982 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 983 Spark Plug: Testing and Inspection Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 984 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 985 clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Heavy Colored Deposits DESCRIPTION: Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on the side facing the intake valve. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap, and reinstall .............................................................................................................................................................. .................................................................................... Normal Operating Conditions NORMAL OPERATING CONDITIONS Normal Operation And Cold(Carbon) Fouling The few deposits present will be probably light tan or slightly gray in color with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000 miles) of operation for non Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 986 platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, have the electrodes filed and regapped, and then reinstalled. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum spark plugs. This would damage the platinum pads which would shorten spark plug life. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit. The rust color deposits can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Oil or Ash Encrusted OIL OR ASH ENCRUSTED Oil Or Ash Encrusted If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of spark plugs. Ash encrusted spark plugs can be cleaned and reused. Premature Electrode Wear - Preignition Damage PREIGNITION DAMAGE Preignition Damage Excessive combustion chamber temperature can cause preignition damage. First, the center electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Other possible causes include ignition timing over-advanced and incorrect spark plug heat range. Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 987 center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Determine if the spark plugs are the correct type, as specified on the VECI label, or if other operating conditions are causing engine overheating. Red, Brown, Yellow or White Deposits - Fuel Additives SCAVENGER DEPOSITS Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed using standard procedures. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and reused. Shiny Yellow Glaze COMBUSTION DEPOSITS A shiny yellow glaze coating on the spark plug insulator is evidence of metallic by-products of fuel combustion, caused by chemical additives in certain fuels. Avoid sudden acceleration with wide open throttle after long periods of low speed driving. Spark plugs with combustion deposits can be cleaned and reused. Spark Plug Inspection ^ Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance Schedules. ^ Spark plugs that have low mileage may be cleaned and reused if not otherwise defective -- SEE Spark Plug Condition. After cleaning, file the center electrode flat with a small point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The spark plug gap is 0.033 to0.038 in. ^ Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Wet Oily Deposits FUEL FOULING A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. White or Gray - Burned or Blistered Insulator SPARK PLUG OVERHEATING Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 988 Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in. per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug overheating. Also check for lean air-fuel mixture. Check the torque value of the plugs to ensure good plug-engine seat contact. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 989 Spark Plug: Adjustments Setting Spark Plug Electrode Gap Fig.2 Setting Spark Plug Electrode Gap Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground -- center electrode. Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap .............................................................................................................................................. ............................................. 0.033 to 0.038 in Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 990 Spark Plug: Service and Repair CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. CAUTION: Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. SPARK PLUG REMOVAL 1. Remove the spark plug using a quality socket with a rubber or foam insert. 2. Inspect the spark plug condition. SPARK PLUG CLEANING Spark plugs that have low mileage may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. SPARK PLUG INSTALLATION 1. To avoid cross threading, start the spark plug into the cylinder head by hand. 2. Tighten spark plugs to 28 Nm (20 ft lb) torque. 3. Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube. 4. Connect coil. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Correct compression pressure is 170-225 psi. Compression pressure should not vary more than 25% from cylinder to cylinder. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 994 Compression Check: Testing and Inspection Perform compression test with engine at normal operating temperature, spark plugs removed and throttle wide open. Standard compression pressure is 170-225 psi. The minimum compression pressure is 100 psi with a maximum variation between highest and lowest cylinders of 25 percent. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments Hydraulic lash adjusters are used; no adjustment is necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Description and Operation Timing Belt: Description and Operation Timing Belt Skipped 1 Tooth or More Trouble Code Name of Code: Timing Belt Skipped 1 Tooth or More When Monitored: With the engine running, every 44ms an inhibit condition is looked for (wide open throttle, large change in rpm, large change in MAP, cold engine, insufficient start to run time, rpm outside given windows). If an inhibit condition does not exist, the misalignment between the camshaft and crankshaft is monitored. Set Condition: When the camshaft position sensor is offset from the crankshaft position sensor one tooth or more. Theory of Operation: The powertrain control module monitors the relationship between two signals, one from the camshaft sensor and one from the crankshaft sensor. If the signals indicate misalignment, a trouble code matures and turns on the malfunction indicator lamp. A misalignment is detected by checking the current alignment against the initial build value stored in the EEPROM of the PCM. This initial build value is established by the PCM when the engine is running in a steady state operating mode. The initial build value is in a reset state at module manufacturing and is set by the PCM. Possible Causes: - Valve timing out of specifications - Camshaft's relative position not relearned (DRB function) after one of the following have been serviced: cam, cam sprocket, timing belt, tensioner, cylinder head, head gasket, crank sprocket, crankshaft, cylinder block or the PCM. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation Timing Belt: Service and Repair Timing Belt Removal and Installation NOTE: With the timing belt removed, avoid turning the camshaft or crankshaft. If movement is required, exercise extreme caution to avoid valve damage caused by piston contact. REMOVAL Fig. 54 Timing Belt Replacement Remove timing belt in numbered sequence as shown, noting the following: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1003 Fig. 55 Crankshaft Pulley Removal 1. Remove crankshaft pulley as shown. 2. Remove power steering pump from the bracket with hose attached and secure out of the way. 3. Place a suitable jack and wood block beneath engine and slightly raise engine to remove engine mount bracket. 4. Align timing marks on camshaft intake and exhaust sprockets before loosening belt tensioner to remove timing belt, Ensure camshaft and crankshaft are not rotated after belt is removed. 5. When belt tensioner is removed, it is necessary to compress the plunger into the tensioner body: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1004 Fig. 57 Timing Belt Tensioner Compression a. Place tensioner in a suitable vise and slowly compress the plunger. b. Index tensioner in vise the same way it is installed on engine to ensure proper pin orientation when installed on engine. c. When plunger is compressed into tensioner body, install a pin through body and plunger to retain plunger in place until tensioner is installed. CAUTION: Do not loosen, remove or tighten tensioner pivot bolt. If this bolt is disturbed, entire pivot bracket assembly must be replaced. INSTALLATION Reverse removal procedure to install noting: Fig. 59 Crankshaft Sprocket Alignment 1. Set the crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing. 2. Using a suitable wrench, move crankshaft to 1/2 notch before TDC. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1005 3. Set the camshaft timing marks by aligning the notches on sprockets. Fig. 60 Timing Belt Installation 4. Install timing belt, starting at crankshaft, around water pump sprocket, idler pulley, camshaft pulleys and tensioner pulley. 5. Move crankshaft sprocket to TDC to take up belt slack. 6. Install belt tensioner to engine block but do not tighten fasteners. 7. Using a suitable torque wrench on the tensioner pulley, torque to 28 ft.-lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1006 Fig. 61 Timing Belt Adjustment 8. With torque being applied to the tensioner pulley, move the tensioner up against the tensioner pulley bracket and torque fasteners to 23 ft.-lbs. 9. Pull the tensioner plunger pin. Pretension is proper when pin can be easily removed or installed. 10. Rotate crankshaft two revolutions and inspect alignment of timing marks. If not proper, repeat procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1007 Timing Belt: Service and Repair Camshaft and Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist Drive Belt: Customer Interest Drive Belt - Momentary Loss of Power Steering Assist NO: 07-04-97 GROUP: Accessory Belt DATE: Jun. 6, 1997 SUBJECT: Momentary Loss Of Power Steering Assist When Driving Through Heavy Rain - Deep Puddles MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Momentary loss of power steering assist when driving through heavy rain and/or deep puddles. Loss of power steering is caused by water intrusion into the accessory drive belt area. DIAGNOSIS: Inspect the belt for glazing and/or cracks, if either is found replace the belt following the repair procedure found in the 1997 Neon Service Manual (Publication No. 81-270-7025) Page 7-21. Determine the road conditions the driver of the vehicle was encountering at the time the loss of power assist was experienced. If the driver indicates the loss of power steering assist was during times of heavy rain or deep puddles, perform the Repair Procedure. PARTS REQUIRED: AR(1) 04612247 Belt, Accessory Drive - Power steering and A/C Compressor REPAIR PROCEDURE: This bulletin involves correcting the tension on the power steering accessory drive belt. 1. Loosen the power steering pump locking bolts A and B and pivot bolt C (Illustration) to allow adjustment of belt tension. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist > Page 1016 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square hole "D" on the power steering pivot bracket. Adjust the tension as follows: Belt tension with no belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 100 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). Belt tension with belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 135 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). C. Start the engine and allow the vehicle to idle for 15 minutes to allow the belt to seat. D. Repeat the belt tensioning procedure, set belt tension to 135 lb. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-11-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist Drive Belt: All Technical Service Bulletins Drive Belt - Momentary Loss of Power Steering Assist NO: 07-04-97 GROUP: Accessory Belt DATE: Jun. 6, 1997 SUBJECT: Momentary Loss Of Power Steering Assist When Driving Through Heavy Rain - Deep Puddles MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Momentary loss of power steering assist when driving through heavy rain and/or deep puddles. Loss of power steering is caused by water intrusion into the accessory drive belt area. DIAGNOSIS: Inspect the belt for glazing and/or cracks, if either is found replace the belt following the repair procedure found in the 1997 Neon Service Manual (Publication No. 81-270-7025) Page 7-21. Determine the road conditions the driver of the vehicle was encountering at the time the loss of power assist was experienced. If the driver indicates the loss of power steering assist was during times of heavy rain or deep puddles, perform the Repair Procedure. PARTS REQUIRED: AR(1) 04612247 Belt, Accessory Drive - Power steering and A/C Compressor REPAIR PROCEDURE: This bulletin involves correcting the tension on the power steering accessory drive belt. 1. Loosen the power steering pump locking bolts A and B and pivot bolt C (Illustration) to allow adjustment of belt tension. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist > Page 1022 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square hole "D" on the power steering pivot bracket. Adjust the tension as follows: Belt tension with no belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 100 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). Belt tension with belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 135 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). C. Start the engine and allow the vehicle to idle for 15 minutes to allow the belt to seat. D. Repeat the belt tensioning procedure, set belt tension to 135 lb. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-11-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 241196 > Jul > 96 > A/C Unit - Air Whistle During Fresh Air Mode Housing Assembly HVAC: All Technical Service Bulletins A/C Unit - Air Whistle During Fresh Air Mode NO.: 24-11-96 GROUP: Heater & A/C DATE: Jul. 12, 1996 SUBJECT: Air Whistle In A/C Unit During Fresh Mode And Higher Blower Speeds MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Some Neons may experience an air whistle at higher blower speeds with the fresh (outside) air setting. This is caused by an air leak between the air inlet housing and the inlet to the blower scroll cage. DIAGNOSIS: To verify condition, select fresh (outside) air and turn the blower control to the highest setting. With the glove box door removed (To remove door, see step 1 of Repair Procedure), push on the joint seam between the inlet housing and the top of the blower motor scroll cage (See Illustration). If the air whistle stops, proceed to the Repair Procedure. PARTS REQUIRED: AR NPN "Dum-Dum" Sealer (3M Strip Calk P/N 08578 or equivalent) REPAIR PROCEDURE: This bulletin involves sealing the joint seam between the air inlet housing and the inlet to the blower scroll. 1. With the glove box door open, remove the door by pushing on the ends of the box to allow the bumpers to clear the instrument panel surface. 2. Using the "Dum-Dum" sealer, seal the area shown in the illustration. Make sure that the joint seam is completely sealed. 3. Install the glove box door. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 241196 > Jul > 96 > A/C Unit - Air Whistle During Fresh Air Mode > Page 1028 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-32-92 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 241196 > Jul > 96 > A/C Unit - Air Whistle During Fresh Air Mode > Page 1034 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-32-92 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > A/C Belt Tension Drive Belt: Specifications A/C Belt Tension Tension, lbs. New ..................................................................................................................................................... .................................................................. 137-159 Used ................................................................... ..................................................................................................................................................... 93-115 Deflection, Inch @ 22 lbs. New ..................................................................................................................................................... ................................................................ 0.32-0.35 Used ................................................................... ................................................................................................................................................. 0.39-0.43 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > A/C Belt Tension > Page 1037 Drive Belt: Specifications Alternator Belt Tension Tension, lbs. New ..................................................................................................................................................... .................................................................. 110-160 Used ................................................................... ..................................................................................................................................................... 90-110 Deflection, Inch @ 22 lbs. New ..................................................................................................................................................... ................................................................ 0.30-0.41 Used ................................................................... ................................................................................................................................................. 0.35-0.47 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > A/C Belt Tension > Page 1038 Drive Belt: Specifications Power Steering Belt Tension Tension, lbs. New ..................................................................................................................................................... .................................................................. 137-159 Used ................................................................... ..................................................................................................................................................... 93-115 Deflection, Inch @ 22 lbs. New ..................................................................................................................................................... ................................................................ 0.32-0.35 Used ................................................................... ................................................................................................................................................. 0.39-0.43 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad Air Cleaner Fresh Air Duct/Hose: Customer Interest Fresh Air Duct - Contacts Hood Insulator Pad NO: 14-05-96 GROUP: Fuel DATE: June 7, 1996 SUBJECT: Wear Marks On Fresh Air Duct And Hood Pad MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES BUILT WITH SPORT/EXPRESSO BUBBLE HOODS AND 2.0L SOHC ENGINES. SYMPTOM/CONDITION: Wear marks on either the fresh air duct or hood pad, due to contact between the two components may be visible. The contact between the fresh air duct and hood pad do not result in a functional problem, but the indentations may be objectional to the customer. PARTS REQUIRED: 1 4669962 Duct, Fresh Air REPAIR PROCEDURE: This bulletin involves the installation of a new fresh air duct which provides additional clearance. 1. Remove the plastic wing nut from the fresh air duct mount. See Illustration. 2. Remove the fresh air duct from the air cleaner box. 3. Install new fresh air duct (P/N 4669962) in the air cleaner box. CAUTION: THE FRESH AIR DUCT MUST BE COMPLETELY SNAPPED INTO THE AIR CLEANER BOX. VERIFY THAT THE DUCT IS FIRMLY IN PLACE. 4. Install the wing nut, while pushing down in the marked area of the fresh air duct. See Illustration. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad > Page 1049 TIME ALLOWANCE: Labor Operation No: 14-10-29-92 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Fresh Air Duct - Contacts Hood Insulator Pad NO: 14-05-96 GROUP: Fuel DATE: June 7, 1996 SUBJECT: Wear Marks On Fresh Air Duct And Hood Pad MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES BUILT WITH SPORT/EXPRESSO BUBBLE HOODS AND 2.0L SOHC ENGINES. SYMPTOM/CONDITION: Wear marks on either the fresh air duct or hood pad, due to contact between the two components may be visible. The contact between the fresh air duct and hood pad do not result in a functional problem, but the indentations may be objectional to the customer. PARTS REQUIRED: 1 4669962 Duct, Fresh Air REPAIR PROCEDURE: This bulletin involves the installation of a new fresh air duct which provides additional clearance. 1. Remove the plastic wing nut from the fresh air duct mount. See Illustration. 2. Remove the fresh air duct from the air cleaner box. 3. Install new fresh air duct (P/N 4669962) in the air cleaner box. CAUTION: THE FRESH AIR DUCT MUST BE COMPLETELY SNAPPED INTO THE AIR CLEANER BOX. VERIFY THAT THE DUCT IS FIRMLY IN PLACE. 4. Install the wing nut, while pushing down in the marked area of the fresh air duct. See Illustration. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad > Page 1055 TIME ALLOWANCE: Labor Operation No: 14-10-29-92 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Fig. 104 Air Intake Duct Fig. 105 Removal/Installation of Air Inlet Duct NOTE: Neon vehicles do not use a heated air inlet system. The PCM adjusts fuel injector pulse width and ignition timing to compensate for different ambient temperatures. NOTE: The air cleaner attaches to a bracket on the rear of the cylinder head. An ambient air duct supplies underhood air for the engine. REMOVAL 1. Remove air intake tube (Fig. 104) from air cleaner and intake manifold (Fig. 105). Fig. 106 Removal/Installation Air Cleaner Front Housing and Element 2. Tighten clasps on top of air cleaner housing. Rotate front of housing forward then lift front away from air cleaner housing (Fig 106). 3. Remove air cleaner element from front housing (Fig. 106). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1059 INSTALLATION 1. Install air cleaner element into front housing. 2. Rotate front of housing forward then lower into place and locate tabs in slots. - Fasten clasps on top of air cleaner housing. - Install air intake duct at air cleaner and intake manifold. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1064 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 12 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) 6. Replace Pressure test port cap when finished releasing pressure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Oil Filter Application Change Oil Filter: Technical Service Bulletins Engine - Oil Filter Application Change NO: 09-03-96 GROUP: Engine DATE: Mar. 1, 1996 SUBJECT: 2.0L/2.4L Engine Oil Filter Application THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-05-95 DATED APR. 7, 1995 AND 09-15-95 DATED JUN. 30, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS INCLUDE ADDITIONAL MODELS AND ADDITIONAL INFORMATION IN THE DISCUSSION. MODELS: 1995 - 1996 (JA) Breeze/Cirrus/Stratus 1995 - 1996 (PL) Neon 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager 1996 (GS) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L OR 2.4L ENGINE EXCEPT (FJ) AVENGER/SEBRING COUPE/TALON. DISCUSSION: Vehicles equipped with a 2.0L or 2.4L engine now have oil filter P/N 4105409 installed when shipped from the assembly plant. This oil filter is smaller in diameter and shorter than oil filter, P/N 5281090, commonly found on most Chrysler products. The smaller oil filter, P/N 4105409, is specified for the applications listed above to provide additional ground clearance. It should be used whenever a filter is changed, regardless of what filter was on the vehicle before service. Failure to use the correct oil filter may result in oil filter damage. The smaller oil filter, P/N 4105409, must be changed every time the oil is changed on all 2.4L engine equipped vehicles and 2.0L equipped JA and GS vehicles. Filter maintenance intervals have not changed for any other vehicles. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair Heater Hose: Service and Repair CAUTION: When removing hoses from heater core inlet or outlet nipples DO NOT exert excess pressure. The heater core may become damaged and leak engine coolant. NOTE: Review Cooling System Precautions before proceeding with this operation. REMOVAL 1. Drain engine cooling system. 2. Remove clamp at end of heater hose to be removed. Heater Hose Quick Connect 3. ON Right Hand Drive (RHD) vehicles, heater hoses at the heater core connection have quick connects. The quick connect consist of two pieces; a quick connect and insert. The quick connect is removed by compressing the insert with a pliers, and pulling the quick connect free of the insert/nipple. Carefully compressed insert pulling the quick connect from connector nipple. The insert will remain on the connector nipple as the quick connect is removed. 4. Remove the heater hose clamp from the heater hose at the block and remove hose. INSTALLATION NOTE: The insert should be removed from the connector nipple and placed inside of the quick connect before reassembly. For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation Hose/Line HVAC: Description and Operation DISCHARGE LINE Discharge Line The discharge line is the line that goes from the compressor to the condenser. It has no serviceable parts except the rubber 0-rings. If the line is found to be leaking or is damaged it must be replaced as an assembly. LIQUID LINE Liquid/Suction Line The liquid line is the line that goes from the condenser to the drier. It has no serviceable parts except the rubber 0-rings. If the line is found to be leaking or is damaged it must be replaced as an assembly. SUCTION LINE The suction line is the large line that connects to the expansion valve and goes to the compressor. It also has a small line that goes to the filter/ drier. The suction line uses a gasket on the expansion valve side and rubber 0-rings on all other connections. There are no serviceable parts on the suction line other than the rubber 0-rings and expansion valve gasket. If the line is found to be leaking or is damaged it must be replaced as an assembly. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Page 1076 Hose/Line HVAC: Service and Repair HANDLING TUBING AND FITTINGS Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and moisture can enter the system when it is opened for repair or replacement of lines or components. The refrigerant oil will absorb moisture readily out of the air. This moisture will convert to acids within a closed system. CAUTION: The system must be completely empty before opening any fitting or connection on the refrigerant system. Open fittings with caution even after system has been emptied. If pressure is noticed as a fitting is loosened, tighten fitting and evacuate system again. BENDING FLEX HOSE A good rule for the flexable hose lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharper bends will reduce the flow of the refrigerant. The flexible hose lines should be routed at least 3 inches away from exhaust manifolds. Inspect all flexible hose lines to make sure they are in good condition and properly routed. CAUTION: The use of correct wrenches when making connections is very important. Improper wrenches or the improper use of wrenches can damage the fittings. INTERNAL DAMAGE The internal parts of the A/C system will remain stable as long as moisture free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture, or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. OPENING SYSTEM When it is necessary to open the refrigeration system, have everything needed to service the system ready. The system should not be left open any longer than necessary. Cap or Plug all lines and fittings as soon as they are opened. This will prevent the entrance of dirt and moisture into the system. All new lines and components should be capped or sealed until they are ready to be used. CAUTION: All tools, including the refrigerant dispensing manifold, the manifold gauge set, and test hoses should be kept dry. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Use new brake fluid only, to top off the master cylinder or refill system. Never use reclaimed fluid, unmarked or unspecified fluid, fluid not meeting SAE/DOT standards, fluid marked 70R1, or fluid from a container that has been left open. Brake Fluid Type DOT 3 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations Coolant: Technical Service Bulletins Engine - Coolant Recommendations NO: 07-03-97 GROUP: Cooling DATE: May 9, 1997 SUBJECT: Engine Coolant Usage THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-05-93 DATED NOV. 26, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1993 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-94000). THE COMPLETE BULLETIN IS REVISED. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1997 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger/ Power Ram/Power Ram Cab & Chassis 1989 - 1993 (AG) Daytona 1989 (AH) Lancer/LeBaron GTS 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1997 (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1997 (BR) Ram Truck 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1989 - 1992 (MJ) Comanche 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1997 (PR) Prowler 1992 - 1997 (SR) Viper/Viper Coupe 1997 (TJ) Wrangler 1989 - 1997 (XJ) Cherokee 1989 - 1995 (YJ) Wrangler 1993 - 1997 (ZJ) Grand Cherokee DISCUSSION: Some owners have expressed interest in using engine coolants made with propylene glycol instead of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals. Based on recent test data, most owners should not experience significant effects on cooling system performance when using propylene glycol based coolant. The use of national brand propylene glycol based engine coolant that meets the same Chrysler ethylene glycol specification of MS-7170 (or equivalent ASTM D5216) is acceptable for Chrysler built vehicles. NOTE: ANTIFREEZE SOLD FOR PROTECTING PLUMBING ETC. (RV ANTIFREEZE) IS NOT A SUITABLE ENGINE COOLANT. However, owners should be discouraged from changing their engine coolant prior to the regularly scheduled maintenance period. Prematurely changing engine coolant unnecessarily adds to the risk of environmental exposure. Sufficient freeze protection for the region should be maintained. However, do not use more than a 55% solution (-35 F, -37 C). Use the chart that accompanies the propylene glycol coolant, since a higher concentration is required to obtain the same freeze points as ethylene glycol coolant. If the temperatures for your region fall below this, use ethylene glycol coolant. Under severe driving conditions (towing a trailer in hot weather etc.) there may be a slight loss in cooling performance. If this is noticed, the system should be changed back to ethylene glycol coolant. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations > Page 1085 The two types of coolant should not be mixed. The standard testers for measuring freeze protection will not provide an accurate reading when this occurs. If the cooling system is changed to propylene glycol, all the ethylene glycol coolant should be removed using an approved cooling system flush procedure. The freeze protection of propylene glycol cannot be measured with a standard cooling system hydrometer. A refractometer or hydrometer calibrated for propylene glycol is the preferred test tool. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Page 1086 Coolant: Specifications Coolant Capacity, Qts. ......................................................................................................................... ............................................................................. 7.4 Radiator Cap Relief Pressure,lbs .................... .............................................................................................................................................................. ...... 16 Thermo. Opening Temp., °F .................................................................................................... ........................................................................................ 195 Fuel Tank, Gals. .................................. .............................................................................................................................................................. .............. 12.5 Engine Oil Refill, Qts. [03] ............................................................................................ ................................................................................................... 4.5 Auto. Transaxle Oil, Qts.[02] ..... .............................................................................................................................................................. ....................... [01] Man. Transaxle Oil, Pts. ....................................................................................... ...................................................................................................... 4.0-4.6 [01] -- Oil change only, 4.0 qts. After overhaul: except fleet models, 8.9 qts., fleet models, 9.2 qts. [02] -- Approximate make final inspection with dipstick. [03] -- Includes oil filter. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1091 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1092 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1093 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1094 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1095 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Estimated service refill ......................................................................................................................... ............................................................. 3.8L (4.0 Qt) Overhaul refill with torque converter ................. ............................................................................................................................................... 8.2L (8.8 Qt) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1098 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ............................................................................................................ ................................................................................... MOPAR ATF Type 9602 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid .............................................................................................................................. .......................................................... 2.1L (4.4 Pints) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1103 Fluid - M/T: Fluid Type Specifications Transmission Fluid .............................................................................................................................. ............................................ MOPAR Type MS 9417 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Mechanical Specifications Engine Oil: Mechanical Specifications VISCOSITY Below 38° C (100° F) ........................................................................................................................... ............................................................ 5W-30 Above 38° C (100° F) .................................................. ................................................................................................................................... 10W-30 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Mechanical Specifications > Page 1108 Engine Oil: Pressure, Vacuum and Temperature Specifications Oil Pressure Specifications Curb Idle: 25 kPa (4 psi) minimum 3000 RPM: 170-550 kPa (25-80 psi) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Mechanical Specifications > Page 1109 Engine Oil: Capacity Specifications Engine Oil Without Filter Change .......................................................................................................................... ............................................................. 3.8L (4.0 Qt) With Filter Change ............................................ .............................................................................................................................................. 4.25L (4.5 Qt) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Mechanical Specifications > Page 1110 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ................................................... SH, GF-1 or Above Above -10°F (-23°C)......................................... .......................................................................................................................................................... 10W-30 Below 100°F (38°C)................................................................................................................ ..................................................................................... 5W-30 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Fluid: Customer Interest Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 1119 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1125 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1126 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1127 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Fluid: All Technical Service Bulletins Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 1132 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1138 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1139 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 1140 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications Refrigerant: Specifications A/C Refrigerant Specifications A/C Refrigerant Specifications Refrigerant Capacity 1.75 lb (US) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications Refrigerant Oil: Specifications Fluid Specifications Fluid Specifications Ounces Viscosity 4.75 oz (US) ND8 PAG Polyalkaline Glycol Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1147 Refrigerant Oil: Service and Repair It is important to have the correct amount of oil in the A/C system to ensure proper lubrication of the compressor. Too little oil will result in damage to the compressor. Too much oil will reduce the cooling capacity of the system and consequently result in higher discharge air temperatures. NOTE: The oil used in the compressor is ND8 PAG R-134a refrigerant oil. Only refrigerant oil of the same type should be used to service the system. Do not use any other oil. The oil container should be kept tightly capped until it is ready for use. Tightly cap afterwards to prevent contamination from dirt and moisture. Refrigerant oil will quickly absorb any moisture it comes in contact with. Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. It will not be necessary to check oil level in the compressor or to add oil unless there has been an oil loss. Oil loss at a leak point will be evident by the presence of a wet, shiny surface around the leak. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Wheel Bleed Sequence LR,RF,RR,LF Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding Brake Bleeding: Service and Repair About Brake System Bleeding BASE BRAKE SYSTEM BLEEDING Bleeding the hydraulic brake system is necessary if air has entered the system. A few causes for this condition are low fluid level, a hydraulic fluid leak, a hydraulic line is opened, or replacement of a hydraulic system component. Symptoms can be noted by an improper or loss of brake operation, and/or a low or spongy brake pedal. Flushing the hydraulic brake system is necessary if contaminants are found in the hydraulic system. A few causes for hydraulic system contamination are moisture, age of hydraulic system parts and fluid, or improper fluid used in the system. Symptoms can be noted by an improper or loss of brake operation, swollen and deteriorated cups and other rubber parts, and/or a discoloration of the brake fluid. The hydraulic fluid is bled or flushed from the system through bleeder valves located on the calipers, wheel cylinders, and some master cylinders. When bleeding the hydraulic brake system, use only specified brake fluid, and never reuse old brake fluid removed from the system. PRESSURE BLEEDING Pressure bleeding is recommended for all hydraulic brake systems. It is the fastest method because the master cylinder is automatically fed brake fluid from the pressure bleeder reservoir, and no pedal pumping is needed so only one person is required to perform the procedure. However, if pressure bleeding equipment is not available, the hydraulic system may be bled as described under "Manual Bleed." When pressure bleeding, to prevent air from getting into the hydraulic system, do not shake the pressure tank. Set the tank in the required location, bring the air hose to the tank, and do not move it during the bleeding operation. The tank should be kept at least one-third full. The bleeder valve should be opened at least one full turn, and intermittently closed at about four-second intervals. This gives a whirling action to fluid in the hydraulic system, and helps expel the air. Refer to Hydraulic Brake System/Specifications for proper wheel bleeding sequence. PRECAUTIONS Normal pressure from the pressure bleeder should not be greater than about 35 PSI. On vehicles equipped with plastic reservoirs, do not exceed 25 PSI bleeding pressure. On models with hold-off valves contained in the combination valve, the valve stem on the outside of the combination valve must be held in position during bleeding using valve holding tool No. C-4121, or equivalent. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 1153 Brake Bleeding: Service and Repair Base Brake System Bleeding On models with power brakes, bleed the hydraulic system without the engine running. Reduce vacuum in the power unit to zero by pumping the brake pedal several times with the engine Off. 1. Ensure master cylinder reservoir is full. 2. Raise and support vehicle. 3. Position a drain pan under the wheel being bled. 4. Have an assistant depress the brake pedal with a slow even strokes until pressure is felt, then hold it. CAUTION: Do not depress brake pedal fully to the end of the master cylinder stroke. This may cause damage to the master cylinder. 5. Starting at the bleeder screw farthest from the master cylinder, using a suitable wrench, open the bleeder valve one full turn. Watch for air bubbles in the fluid, and listen for air escaping from the system. 6. With the brake pedal still depressed, close the bleeder valve. 7. Have the assistant pump the brake pedal several times, then repeat procedure until air no longer is noticed when bleeder is opened. CAUTION: Do not depress brake pedal fully to the end of the master cylinder stroke, this may cause damage to the master cylinder. 8. Repeat previous steps for all bleeders following the wheel bleeding sequence specified in Hydraulic Brake System/Specifications. Ensure all air is removed from the hydraulic system. CAUTION: While bleeding the system, inspect brake fluid supply in the master cylinder often so as not to allow the master cylinder to run dry. 9. Upon completion of hydraulic system bleeding proceed as follows: a. Ensure the master cylinder reservoir is full. Add suitable brake fluid as needed, and securely reinstall the master cylinder cap. b. Lower the vehicle. Ensure brakes operate properly and pedal is firm. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - 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. - 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, use proper and safe service procedures . Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: 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 disarm the system. NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). 1. Disconnect and isolate the battery negative (ground) cable. 2. 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 air-bag deployment and possible personal injury. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 1159 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming WARNING: Before attempting to diagnose, remove or install any airbag system components, first disconnect and isolate battery ground cable, then wait at least 2 minutes prior the performing any service. - Failure to do so may result in airbag deployment or personal injury. 1. Connect the scan tool to the Data Link connector which is located on the left side kick panel just above the hood release. 2. Turn the ignition key to the ON position. Exit vehicle with the scan tool. Use the latest version of the diagnostic cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative remote terminal. 4. Using the scan tool, read and record the active diagnostic trouble code data. 5. Read and record any stored diagnostic trouble codes. 6. Refer to Powertrain Management/Computers and Controls/Body Control Module if any diagnostic trouble codes are found in Step 4 and Step 5. 7. Erase stored diagnostic trouble codes if there are no active diagnostic trouble codes. If problems remain, diagnostic trouble codes will not erase. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. If the airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations Fuse: Locations The fuse panel is located behind the left side of the instrument panel, left of the steering column. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1166 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1167 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1168 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1169 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1170 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1171 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1172 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1173 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1174 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1175 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1176 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1177 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1178 Fuse: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1179 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1180 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1181 Fuse: Connector Views Fuse/Fuse Block (Part 1 Of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1182 Fuse/Fuse Block (Part 2 Of 2) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1183 Fuse: Electrical Diagrams Fuse/Fuse Block (Part 1 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1184 Fuse/Fuse Block (Part 2 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1185 Fuse/Fuse Block (Part 3 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1186 Fuse/Fuse Block (Part 4 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1187 Fuse/Fuse Block (Part 5 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1188 Fuse/Fuse Block (Part 6 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1189 Fuse/Fuse Block (Part 7 Of 7) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations Fuse Block: Locations The fuse panel is located behind the left side of the instrument panel, left of the steering column. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1195 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1196 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1197 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1198 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1199 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1200 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1201 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1202 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1203 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1204 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1205 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1206 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1207 Fuse Block: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1208 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1209 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1210 Fuse Block: Connector Views Fuse/Fuse Block (Part 1 Of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1211 Fuse/Fuse Block (Part 2 Of 2) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1212 Fuse Block: Electrical Diagrams Fuse/Fuse Block (Part 1 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1213 Fuse/Fuse Block (Part 2 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1214 Fuse/Fuse Block (Part 3 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1215 Fuse/Fuse Block (Part 4 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1216 Fuse/Fuse Block (Part 5 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1217 Fuse/Fuse Block (Part 6 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1218 Fuse/Fuse Block (Part 7 Of 7) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations Relay Box: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1222 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams Instrument Panel Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Page 1227 Malfunction Indicator Lamp: Description and Operation Fig.1 Data Link (Diagnostic) Connector OPERATION As a functional test, the Malfunction Indicator Lamp (MIL) illuminates at key-on before engine cranking. Whenever the Powertrain Control Module (PCM) sets a Diagnostic Trouble Code (DTC) that affects vehicle emissions, it illuminates the MIL. If a problem is detected, the PCM sends a message over the CCD Bus to the instrument cluster to illuminate the lamp. The PCM illuminates the MIL only for DTC's that affect vehicle emissions. The MIL stays on continuously when the PCM has entered a Limp-In mode or identified a failed emission component. The MIL remains on until the DTC is erased. Also, the MIL either flashes or illuminates continuously when the PCM detects active engine misfire. Addifionally the PCM may reset (turn off) the MIL when one of the following occur: PCM does not detect the malfunction for 3 consecutive trips (except misfire and Fuel system Monitors). - PCM does not detect a malfuction while performing three successive engine misfire or fuel system tests. The PCM performs these tests while the engine is operating within ±375 RPM of and within 10% of the load of the operating condition at which the malfunction was first detected. CIRCUIT OPERATION The Check Engine lamp (Malfunction Indicator Lamp) illuminates when the ignition switch is in the ON position and prior to starting the vehicle. The lamp will turn off after the vehicle is started. If while the vehicle is running a problem is detected in the engine control system the lamp is illuminated. This is accomplished by the Powertrain Control Module (PCM) grounding the G3 circuit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire & Wheel - Runout Tires: Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Tire & Wheel - Runout Wheels: Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front DISASSEMBLE All steps of the hub bearing removal from steering knuckle must be done using a hydraulic arbor press. 1. Install bearing splitter tool No. P334, or equivalent, on steering knuckle and hub/bearing assembly to support steering knuckle when pressing out bearing. Hub, Bearing & Steering Knuckle Supported For Removal Of Hub 2. Position steering knuckle and hub/bearing assembly in vise, support by splitter tool No. P334, or equivalent. 3. Position driver tool No. 6644-2, or equivalent, on small end of hub, then press hub from bearing. The one bearing race may come out with hub when hub is removed from bearing. Hub Bearing Removal 4. Remove bearing splitter from steering knuckle, then place steering knuckle is press supported by press blocks. 5. Place bearing driver tool No. MB-990799, or equivalent, on outer race of hub bearing, then press hub bearing completely out of steering knuckle. 6. Install bearing splitter tool No. P334, or equivalent, on hub so it is between flange of hub and bearing race remaining on hub. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1241 Hub Bearing Race Removal 7. Install assembly into press, then place driver tool on end of hub and press hub out of hub bearing race. ASSEMBLE 1. Install new bearing into bore of steering knuckle so it is square with bore, then place steering knuckle in press with receiver tool No. C-4698-2, or equivalent, supporting steering knuckle. 2. Place driver tool No. 5052, or equivalent, on outer race of hub, then press hub bearing into steering knuckle until it is fully bottom in bearing bore of steering knuckle. 3. Install hub bearing retaining snap ring into groove in hub bearing bore of steering knuckle. Ensure snap ring is fully seated. Hub Bearing Installation 4. Place steering knuckle with hub bearing installed in press with receiver tool No. MB-990799, or equivalent, supporting inner race of hub bearing. 5. Place hub into hub bearing ensuring it is square with bearing. 6. Place driver tool No. 6522, or equivalent, on front face of hub, then press hub into bearing until it bottoms in hub bearing. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1242 Wheel Bearing: Service and Repair Rear With Rear Disc Brakes The rear hub and bearing are serviced as an assembly. 1. Raise and support vehicle, then remove wheel. 2. Remove caliper and disc. 3. Remove the hub retaining nut, then the hub and bearing assembly. 4. Reverse procedure to install. Tighten nuts and bolts to specifications. With Rear Drum Brakes The rear hub and bearing are serviced as an assembly. 1. Raise and support vehicle, then remove wheel. 2. Remove drum. 3. Remove the hub retaining nut, then the hub and bearing assembly. 4. Reverse procedure to install. Tighten nuts and bolts to specifications. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 1252 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 1258 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 1259 Axle Nut: Specifications Front Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 183 Nm (135 ft. lbs.) Rear Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 217 Nm (160 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Lug Nut Torque Lug Nut Torque Lug Nuts 135 Nm Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Correct compression pressure is 170-225 psi. Compression pressure should not vary more than 25% from cylinder to cylinder. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1268 Compression Check: Testing and Inspection Perform compression test with engine at normal operating temperature, spark plugs removed and throttle wide open. Standard compression pressure is 170-225 psi. The minimum compression pressure is 100 psi with a maximum variation between highest and lowest cylinders of 25 percent. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications Camshaft Bearing Cap ID Camshaft Bearing Cap-Torque Sequence 1. Lubricate bearing journals and cam followers with clean oil and install the camshafts. Install right and left camshaft bearing caps #2 thru #5 and right #6. Tighten M6 fasteners to 12 N.m (105 in. lbs.) in sequence. Camshaft Bearing Cap Sealing 2. Apply Mopar Gasket Maker to No.1 and No.6 bearing caps. Jnstall bearing caps and tighten M8 fasteners to 24 N.m (215 in. lbs.). 3. Bearing cap number 1, must be installed before the camshaft seals can be installed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Torque Torque Camshaft Sprocket Bolt 85 ft.lb Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Camshaft Bearing Cap ID Camshaft Bearing Cap-Torque Sequence 1. Lubricate bearing journals and cam followers with clean oil and install the camshafts. Install right and left camshaft bearing caps #2 thru #5 and right #6. Tighten M6 fasteners to 12 N.m (105 in. lbs.) in sequence. Camshaft Bearing Cap Sealing 2. Apply Mopar Gasket Maker to No.1 and No.6 bearing caps. Jnstall bearing caps and tighten M8 fasteners to 24 N.m (215 in. lbs.). 3. Bearing cap number 1, must be installed before the camshaft seals can be installed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1279 Camshaft: Service and Repair REMOVAL Remove camshaft in numbered sequence, Fig.68, noting the following: 1. Use camshaft sprocket holder and adapter tools No. C-4687 and C-4687-1, or equivalent, to ensure camshaft sprockets do not turn during removal. 2. Mark and identify intake camshaft and exhaust camshaft before removal as they are not interchangeable. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1280 Fig. 69 Camshaft Bearing Caps 3. Loosen camshaft bearing cap attaching bolts in sequence shown in Fig.69, one camshaft at a time. 4. Remove camshaft oil seals using suitable screwdriver to pry seal out. INSTALLATION Fig. 70 Camshaft Oil Seal Installation 1. Install new camshaft oil seals using special oil seal seating tools No. MB991554 and MB998713, or equivalents, Fig.70. 2. Ensure piston is not at top dead center when installing camshaft. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1281 Fig. 69 Camshaft Bearing Caps 3. Install camshaft bearing cap attaching bolts in sequence shown in Fig.69, one camshaft at a time. Tighten to specifications. 4. Use camshaft sprocket holder and adapter tools No. C-4687 and C-4687-1, or equivalents, to ensure camshaft sprockets do not turn during installation. Fig. 71 Cylinder Head Cover Installation 5. Install cylinder head cover assembly to head and tighten in sequence shown in Fig.71. Torque in three steps: First to 3.3 ft.-lbs., Then to 6.6 ft.-lbs., Finally to 8.9 ft.-lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Shaft Retaining Bolts 250 in.lb Rocker Arm Tighting Torque 200 in.lb Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1285 Rocker Arm Assembly: Service and Repair REMOVAL Fig. 68 Camshaft Replacement Remove camshaft in numbered sequence, Fig.68, noting the following: 1. Use camshaft sprocket holder and adapter tools No. C-4687 and C-4687-1, or equivalent, to ensure camshaft sprockets do not turn during removal. 2. Mark and identify intake camshaft and exhaust camshaft before removal as they are not interchangeable. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1286 Fig. 69 Camshaft Bearing Caps 3. Loosen camshaft bearing cap attaching bolts in sequence shown in Fig.69, one camshaft at a time. 4. Remove camshaft oil seals using suitable screwdriver to pry seal out. INSTALLATION Fig. 70 Camshaft Oil Seal Installation 1. Install new camshaft oil seals using special oil seal seating tools No. MB991554 and MB998713, or equivalents, Fig.70. 2. Ensure piston is not at top dead center when installing camshaft. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1287 Fig. 69 Camshaft Bearing Caps 3. Install camshaft bearing cap attaching bolts in sequence shown in Fig.69, one camshaft at a time. Tighten to specifications. 4. Use camshaft sprocket holder and adapter tools No. C-4687 and C-4687-1, or equivalents, to ensure camshaft sprockets do not turn during installation. Fig. 71 Cylinder Head Cover Installation 5. Install cylinder head cover assembly to head and tighten in sequence shown in Fig.71. Torque in three steps: First to 3.3 ft.-lbs., Then to 6.6 ft.-lbs., Finally to 8.9 ft.-lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Service and Repair Balance Shaft: Service and Repair Fig. 35 Front Case, Oil Pump & Silent Shaft Assembly. DISASSEMBLY Disassemble front case, oil pump and silent shaft in numbered sequence noting the following: 1. Use oil pressure switch socket No. MD998054 or equivalent to remove oil pressure switch. 2. Remove oil pan, refer to Oil Pan Replacement under Engine Lubrication/Service and Repair. 3. Use plug cap socket No. MD998162 or equivalent to remove front case plug cap (17). Fig. 36 Blocking Silent Shaft For Oil Pump Sprocket Removal 4. When removing oil pump driven gear bolt, insert a Phillips screwdriver into plug hole, to block the silent shaft. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Service and Repair > Page 1292 Fig. 30 Removing Silent Shaft Front Bearings. 5. Using silent shaft bearing puller No. MD998371 or equivalent, remove silent shaft front bearing as shown. Fig. 31 Removing Silent Shaft Rear Bearing. 6. Using silent shaft bearing puller No. MD998372 or equivalent, remove right silent shaft rear bearing as shown. Fig. 37 Removing Left Silent Shaft Rear Bearing. 7. Using silent shaft bearing puller No. MD998374 or equivalent, remove left silent shaft rear bearing as shown. INSPECTION 1. Inspect front case for the following: a. Clogged oil passages. b. Damaged or seized left silent shaft front bearing section. c. Cracks or other signs of damage on case. 2. Inspect oil seal lip for wear or damage, replacing as necessary. 3. Test oil switch as follows: a. Connect an ohmmeter between switch terminal and switch body. b. If ohmmeter reads no continuity, replace switch. If ohmmeter reads continuity, proceed to step c. c. Insert a fine wedge into oil switch hole. Ohmmeter should read no continuity when wedge is slightly pressed into hole, If ohmmeter reads continuity, replace switch. 4. On models with turbocharged engine, inspect oil cooler bypass valve as follows: a. Ensure valves move smoothly. Fig. 38 Oil Cooler Bypass Valve. b. Measure dimension L on bypass valve. At room temperature, dimension L should be 1.358 inch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Service and Repair > Page 1293 c. Dip valve in engine oil heated to 212°F. Dimension L should now be at least 1.570 inch. 5. On all models, inspect oil pump as follows: a. Install oil pump gears in front case and rotate gears, ensuring smooth rotation without excessive looseness. b. Check for for ridge wear on surface of oil pump cover. c. Check drive gear and driven gear tip clearance. d. Check side clearance of gears. 6. Inspect silent shaft for the following: a. Clogged oil passages. b. Seized or damaged journal. c. Ensure oil clearance is within specifications. Clearance should be as follows: Right Front, 0.0008 - 0.0024 inch; Right Rear, 0.0008 - 0.0021 inch; Left Front, 0.0002 - 0.0036 inch; Left Rear, 0.0017 - 0.0033 inch. 7. Inspect oil jet and check valve for clogging or damage. ASSEMBLY Reverse removal procedure to install, noting the following: 1. When installing oil jet, ensure nozzle is installed toward the piston. Fig. 39 Installing Left Silent Shaft Rear Bearing. 2. When installing left silent shaft rear bearing, apply clean engine oil to engine block bearing hole and to outer circumference of bearing. Using bearing installation tool No. MD998374 or equivalent, install bearing into cylinder block. Fig. 40 Installing Right Silent Shaft Rear Bearing. 3. When installing right silent shaft rear bearing, apply clean engine oil to engine block bearing hole and to outer circumference of bearing. Using bearing installation tool No. MD998373 or equivalent, install bearing into cylinder block. Ensure oil hole in bearing is aligned with oil hole in cylinder block. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Service and Repair > Page 1294 Fig. 41 Installing Silent Shaft Front Bearing. 4. When installing silent shaft front bearing, apply clean engine oil to engine block bearing hole and to outer circumference of bearing. Using bearing installation tool No. MD998373 or equivalent, install bearing into cylinder block. Ensure oil hole in bearing is aligned with oil hole in cylinder block. 5. When installing oil pump gears, coat gears with clean engine oil, then align mark on drive gear notch with mark on driven gear tooth. 6. Install crankshaft oil seal using oil seal installation tool No. MD998375 or equivalent. 7. Install oil seal (22) and silent shaft oil seal (23) by placing a socket over the top of the seal and pressing it into the case. Fig. 42 Front Case Attaching Bolts. 8. Install front case as follows: a. Place crankshaft front oil seal guide No. MD998285 or equivalent over front end of crankshaft, then apply engine oil to outer circumference of guide. b. Install front case over top of guide, onto cylinder block. Temporarily tighten all bolts except the filter bracket attaching bolts, referring to bolt length chart. c. Install oil filter bracket and the four attaching bolts. d. Tighten all bolts to specifications. 9. When installing driven gear bolt (19), insert a Phillips screwdriver into plug hole on left side of cylinder block, to block the silent shaft. 10. When installing plug cap, place a new O-ring into groove of case, then use plug cap socket No. MD998162 or equivalent to tighten cap. 11. Install oil pan, refer to Oil Pan Replacement under d12. When installing oil pressure switch, coat threads of switch with gasket adhesive. Do not allow hole in end of switch to be covered with adhesive. Install switch using oil pressure switch socket No. MD998054 or equivalent. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting Rod Nut 20 ft.lb NOTE: Plus an additional 1/4 turn. Large End Bore Diameter 2.0075-2.0081 in Total Weight 1.20 lb (US) Bearing Oil Clearance 0.001-.0023 in Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair Harmonic Balancer - Crankshaft Pulley: Service and Repair NOTE: If a gap is found in the crankshaft damper, in the area where the Poly-V Generator belt rides this is normal and is acceptable. REMOVAL 1. Remove accessory drive belts. 2. Raise vehicle on a hoist and remove right inner splash shield. 3. Remove crankshaft damper bolt. Remove damper using the large side of Special Tool 1026 and insert 6827-A. or equivalents. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Page 1301 INSTALLATION 1. Install crankshaft damper using M12-1.75 x 150 mm bolt, washer, thrust bearing and nut from Special Tool 6792, or equivalent. Install crankshaft damper bolt and tighten to 142 Nm (105 ft. lbs.). 2. Install accessory drive belts. 3. Raise vehicle on hoist and install right inner splash shield. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair Piston: Service and Repair PISTON AND CONNECTING ROD ASSEMBLY REMOVAL 1. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Mark piston with matching cylinder number. 2. Remove oil pan. Scribe the cylinder number on the side of the rod and cap for identification. 3. Pistons have stamping in the front half of the piston facing towards the front of engine. The stamping is 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. 4. Pistons and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each connecting rod is centered in cylinder bore. 5. Remove connecting rod cap bolts. Push each piston and rod assembly out of cylinder bore. Be careful not to nick crankshaft journals. 6. After removal, install bearing cap on the mating rod. 7. Piston and Rods are serviced as an assembly. INSTALLATION 1. Before installing pistons and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Page 1305 2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps. 3. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston. Be sure position of rings does not change during this operation. 4. The weight stamp designation L for light or H for heavy assembly will be in the front half of the piston facing toward the front of the engine. 5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston assembly into cylinder bore and guide rod over the crankshaft journal. 6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. 7. Install rod caps. Install cleaned and oiled rod bolts and tighten to 27 Nm (20 ft. lb.) Plus 1/4 turn. CONNECTING RODS 1. See main bearing for measureing and specifiction procedures. CAUTION: Do not rotate crankshaft or the Plastigage may be smeared. The rod bearing bolts should not be reused. 2. Before installing the NEW bolts the threads should be oiled with clean engine oil. 3. Install each bolt finger tight than alternately torque each bolt to assemble the cap properly. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Page 1306 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. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments Hydraulic lash adjusters are used; no adjustment is necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 1314 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 12 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) 6. Replace Pressure test port cap when finished releasing pressure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Shaft Retaining Bolts 250 in.lb Rocker Arm Tighting Torque 200 in.lb Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1318 Rocker Arm Assembly: Service and Repair REMOVAL Fig. 68 Camshaft Replacement Remove camshaft in numbered sequence, Fig.68, noting the following: 1. Use camshaft sprocket holder and adapter tools No. C-4687 and C-4687-1, or equivalent, to ensure camshaft sprockets do not turn during removal. 2. Mark and identify intake camshaft and exhaust camshaft before removal as they are not interchangeable. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1319 Fig. 69 Camshaft Bearing Caps 3. Loosen camshaft bearing cap attaching bolts in sequence shown in Fig.69, one camshaft at a time. 4. Remove camshaft oil seals using suitable screwdriver to pry seal out. INSTALLATION Fig. 70 Camshaft Oil Seal Installation 1. Install new camshaft oil seals using special oil seal seating tools No. MB991554 and MB998713, or equivalents, Fig.70. 2. Ensure piston is not at top dead center when installing camshaft. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1320 Fig. 69 Camshaft Bearing Caps 3. Install camshaft bearing cap attaching bolts in sequence shown in Fig.69, one camshaft at a time. Tighten to specifications. 4. Use camshaft sprocket holder and adapter tools No. C-4687 and C-4687-1, or equivalents, to ensure camshaft sprockets do not turn during installation. Fig. 71 Cylinder Head Cover Installation 5. Install cylinder head cover assembly to head and tighten in sequence shown in Fig.71. Torque in three steps: First to 3.3 ft.-lbs., Then to 6.6 ft.-lbs., Finally to 8.9 ft.-lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-97 > Jun > 97 > Drive Belt Momentary Loss of Power Steering Assist Drive Belt: Customer Interest Drive Belt - Momentary Loss of Power Steering Assist NO: 07-04-97 GROUP: Accessory Belt DATE: Jun. 6, 1997 SUBJECT: Momentary Loss Of Power Steering Assist When Driving Through Heavy Rain - Deep Puddles MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Momentary loss of power steering assist when driving through heavy rain and/or deep puddles. Loss of power steering is caused by water intrusion into the accessory drive belt area. DIAGNOSIS: Inspect the belt for glazing and/or cracks, if either is found replace the belt following the repair procedure found in the 1997 Neon Service Manual (Publication No. 81-270-7025) Page 7-21. Determine the road conditions the driver of the vehicle was encountering at the time the loss of power assist was experienced. If the driver indicates the loss of power steering assist was during times of heavy rain or deep puddles, perform the Repair Procedure. PARTS REQUIRED: AR(1) 04612247 Belt, Accessory Drive - Power steering and A/C Compressor REPAIR PROCEDURE: This bulletin involves correcting the tension on the power steering accessory drive belt. 1. Loosen the power steering pump locking bolts A and B and pivot bolt C (Illustration) to allow adjustment of belt tension. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-97 > Jun > 97 > Drive Belt Momentary Loss of Power Steering Assist > Page 1330 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square hole "D" on the power steering pivot bracket. Adjust the tension as follows: Belt tension with no belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 100 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). Belt tension with belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 135 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). C. Start the engine and allow the vehicle to idle for 15 minutes to allow the belt to seat. D. Repeat the belt tensioning procedure, set belt tension to 135 lb. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-11-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist Drive Belt: All Technical Service Bulletins Drive Belt - Momentary Loss of Power Steering Assist NO: 07-04-97 GROUP: Accessory Belt DATE: Jun. 6, 1997 SUBJECT: Momentary Loss Of Power Steering Assist When Driving Through Heavy Rain - Deep Puddles MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Momentary loss of power steering assist when driving through heavy rain and/or deep puddles. Loss of power steering is caused by water intrusion into the accessory drive belt area. DIAGNOSIS: Inspect the belt for glazing and/or cracks, if either is found replace the belt following the repair procedure found in the 1997 Neon Service Manual (Publication No. 81-270-7025) Page 7-21. Determine the road conditions the driver of the vehicle was encountering at the time the loss of power assist was experienced. If the driver indicates the loss of power steering assist was during times of heavy rain or deep puddles, perform the Repair Procedure. PARTS REQUIRED: AR(1) 04612247 Belt, Accessory Drive - Power steering and A/C Compressor REPAIR PROCEDURE: This bulletin involves correcting the tension on the power steering accessory drive belt. 1. Loosen the power steering pump locking bolts A and B and pivot bolt C (Illustration) to allow adjustment of belt tension. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist > Page 1336 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square hole "D" on the power steering pivot bracket. Adjust the tension as follows: Belt tension with no belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 100 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). Belt tension with belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 135 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). C. Start the engine and allow the vehicle to idle for 15 minutes to allow the belt to seat. D. Repeat the belt tensioning procedure, set belt tension to 135 lb. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-11-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad Hood: All Technical Service Bulletins Fresh Air Duct - Contacts Hood Insulator Pad NO: 14-05-96 GROUP: Fuel DATE: June 7, 1996 SUBJECT: Wear Marks On Fresh Air Duct And Hood Pad MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES BUILT WITH SPORT/EXPRESSO BUBBLE HOODS AND 2.0L SOHC ENGINES. SYMPTOM/CONDITION: Wear marks on either the fresh air duct or hood pad, due to contact between the two components may be visible. The contact between the fresh air duct and hood pad do not result in a functional problem, but the indentations may be objectional to the customer. PARTS REQUIRED: 1 4669962 Duct, Fresh Air REPAIR PROCEDURE: This bulletin involves the installation of a new fresh air duct which provides additional clearance. 1. Remove the plastic wing nut from the fresh air duct mount. See Illustration. 2. Remove the fresh air duct from the air cleaner box. 3. Install new fresh air duct (P/N 4669962) in the air cleaner box. CAUTION: THE FRESH AIR DUCT MUST BE COMPLETELY SNAPPED INTO THE AIR CLEANER BOX. VERIFY THAT THE DUCT IS FIRMLY IN PLACE. 4. Install the wing nut, while pushing down in the marked area of the fresh air duct. See Illustration. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad > Page 1342 TIME ALLOWANCE: Labor Operation No: 14-10-29-92 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad > Page 1348 TIME ALLOWANCE: Labor Operation No: 14-10-29-92 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > A/C Belt Tension Drive Belt: Specifications A/C Belt Tension Tension, lbs. New ..................................................................................................................................................... .................................................................. 137-159 Used ................................................................... ..................................................................................................................................................... 93-115 Deflection, Inch @ 22 lbs. New ..................................................................................................................................................... ................................................................ 0.32-0.35 Used ................................................................... ................................................................................................................................................. 0.39-0.43 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > A/C Belt Tension > Page 1351 Drive Belt: Specifications Alternator Belt Tension Tension, lbs. New ..................................................................................................................................................... .................................................................. 110-160 Used ................................................................... ..................................................................................................................................................... 90-110 Deflection, Inch @ 22 lbs. New ..................................................................................................................................................... ................................................................ 0.30-0.41 Used ................................................................... ................................................................................................................................................. 0.35-0.47 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > A/C Belt Tension > Page 1352 Drive Belt: Specifications Power Steering Belt Tension Tension, lbs. New ..................................................................................................................................................... .................................................................. 137-159 Used ................................................................... ..................................................................................................................................................... 93-115 Deflection, Inch @ 22 lbs. New ..................................................................................................................................................... ................................................................ 0.32-0.35 Used ................................................................... ................................................................................................................................................. 0.39-0.43 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Engine - Excessive Perceived Movement Engine Mount: Technical Service Bulletins Engine - Excessive Perceived Movement NO: 09-05-96 GROUP: Engine DATE: Mar. 22, 1996 SUBJECT: Excessive Engine Motion/Engine Mount Wear Characteristics MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Perceived excessive engine rolling during wide open throttle simulation and/or visible cracks in portions of engine mount rubber isolator. DISCUSSION: The perceived "excessive engine motion" is a design characteristic and is required to maintain adequate isolation of the powertrain noise/vibration from the passenger compartment. Some visible cracks in portions of the engine mount rubber isolator are also design characteristics. The rubber molding process allows excess rubber to fill in the areas around the mount legs. The excess rubber cracks due to the normal motion of the engine mount. The shading in figures 1 and 2 show the areas where cracks are allowable. The cracks do not affect the durability or function of the parts. THE ENGINE MOUNTS SHOULD NOT BE REPLACED FOR EITHER OF THE CONDITIONS DESCRIBED ABOVE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Engine - Excessive Perceived Movement > Page 1357 POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 1358 Engine Mount: Service and Repair FRONT 1. Support engine and transaxle with suitable floor jack. 2. Remove front engine mount through bolt from insulator and crossmember mounting bracket. 3. Remove mass damper, front mount nuts and insulator assembly. 4. Remove front mounting bracket 5. Reverse procedure for installtion and tighten fasteners in this order. a. Tighten bolt 1 to 3 Nm (20 in. lbs.) and bolts 2,3 and 4 to 108 Nm (80 ft. lbs.). b. Tighten bolts 5 and 1 to 54 Nm (40 ft. lbs.). c. Tighten unsulator assembly nuts to 54 Nm (40 ft. lbs.). d. Install mass damper and tighten tio 54 Nm (40 ft. lbs.). e. tighten thru bolt to 54 Nm (40 ft. lbs.). LEFT 1. Raise and support vehicle, then remove left front tire wheel assembly. 2. Remove power distribution center and place aside. 3. Support transaxle with suitable jack, then remove the insulator through bolt from mount. 4. Remove the transmission mount fasteners and remove mount. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 1359 5. Reverse procedure for installation. Before tightening the thru-bolt be sure there is no load in the insulator. Tighten the thru bolt to 108 Nm (80 ft. lbs.). RIGHT 1. Remove purge duty solenoid from engine mount bracket. 2. Remove right engine mount insulator vertical fasteners from frame rail. 3. Carefully support engine/transaxle assembly to relieve pressure on mount. 4. Remove through bolt from insulator, then the insulator. 5. Reverse removal procedure for installtion. Tighten the engine mount to frame rail fasteners to 54 Nm (40 ft. lbs.) Before tightening the thru-bolt be sure there is no load on the insulator. Tighten the thru-bolt to 108 Nm (80 ft. lbs.). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Mechanical Specifications Engine Oil: Mechanical Specifications VISCOSITY Below 38° C (100° F) ........................................................................................................................... ............................................................ 5W-30 Above 38° C (100° F) .................................................. ................................................................................................................................... 10W-30 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Mechanical Specifications > Page 1365 Engine Oil: Pressure, Vacuum and Temperature Specifications Oil Pressure Specifications Curb Idle: 25 kPa (4 psi) minimum 3000 RPM: 170-550 kPa (25-80 psi) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Mechanical Specifications > Page 1366 Engine Oil: Capacity Specifications Engine Oil Without Filter Change .......................................................................................................................... ............................................................. 3.8L (4.0 Qt) With Filter Change ............................................ .............................................................................................................................................. 4.25L (4.5 Qt) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Mechanical Specifications > Page 1367 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ................................................... SH, GF-1 or Above Above -10°F (-23°C)......................................... .......................................................................................................................................................... 10W-30 Below 100°F (38°C)................................................................................................................ ..................................................................................... 5W-30 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Oil Filter Application Change Oil Filter: Technical Service Bulletins Engine - Oil Filter Application Change NO: 09-03-96 GROUP: Engine DATE: Mar. 1, 1996 SUBJECT: 2.0L/2.4L Engine Oil Filter Application THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-05-95 DATED APR. 7, 1995 AND 09-15-95 DATED JUN. 30, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. REVISIONS INCLUDE ADDITIONAL MODELS AND ADDITIONAL INFORMATION IN THE DISCUSSION. MODELS: 1995 - 1996 (JA) Breeze/Cirrus/Stratus 1995 - 1996 (PL) Neon 1996 (JX) Sebring Convertible 1996 (NS) Town & Country/Caravan/Voyager 1996 (GS) Chrysler Voyager (European Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L OR 2.4L ENGINE EXCEPT (FJ) AVENGER/SEBRING COUPE/TALON. DISCUSSION: Vehicles equipped with a 2.0L or 2.4L engine now have oil filter P/N 4105409 installed when shipped from the assembly plant. This oil filter is smaller in diameter and shorter than oil filter, P/N 5281090, commonly found on most Chrysler products. The smaller oil filter, P/N 4105409, is specified for the applications listed above to provide additional ground clearance. It should be used whenever a filter is changed, regardless of what filter was on the vehicle before service. Failure to use the correct oil filter may result in oil filter damage. The smaller oil filter, P/N 4105409, must be changed every time the oil is changed on all 2.4L engine equipped vehicles and 2.0L equipped JA and GS vehicles. Filter maintenance intervals have not changed for any other vehicles. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair Oil Pan: Service and Repair Fig. 92 Oil Pan & Screen Replacement REMOVAL Remove oil pan and oil screen in numbered sequence, noting the following: 1. Once all oil pan bolts are removed, use oil pan separator No. MD998727 or equivalent and a hammer to loosen pan. Do not use a screwdriver or a chisel to perform this task, as damage to oil pan flange may result. 2. Remove pan by placing a brass bar at corner of separator tool and striking it with a hammer. INSPECTION Replace the oil pan if damaged or cracked. Ensure screen is not clogged, cracked or damage. INSTALLATION Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Page 1375 Reverse removal procedure to install. When installing oil pan, ensure mating surfaces are clean, then apply gasket adhesive into groove in oil pan flange. Do not allow adhesive to cover bolt holes. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation Fig.3 Gauge LED Locations The fuel, temperature and ammeter gauges are equipped with a Light Emitting Diode (LED) mounted in each of the gauge dials. This diode will illuminate and alert the driver that the system is malfunctioning. The electronic sensor circuit is mounted on the gauge housing. The printed circuit board is permanently attached and is not serviceable. If the LED is malfunctioning, the gauge and the printed circuit board must be replaced as an assembly. The oil pressure warning switch, mounted on the engine, is controlled by engine oil pressure. When engine oil pressure is high (normal operating condition) the switch is held in the Off position allowing no current to flow to the oil pressure warning lamp on the instrument panel. When engine oil pressure is low, the switch is in the On position allowing current to flow to the oil pressure warning lamp on the instrument panel causing the instrument panel to be illuminated. When the switch is in the Off position, it completes the circuit for the electric choke heater. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation CIRCUIT OPERATION The low oil pressure lamp is used to indicate to the operator that the engine oil pressure has dropped below a predetermined pressure. Power for the lamp is provided on the G5 circuit which also powers the other warning lamps. When the oil pressure is low the normally OPEN oil pressure switch CLOSES completing a path to ground. The oil pressure switch is case grounded to the engine block. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Service and Repair Oil Pump: Service and Repair Fig. 35 Front Case, Oil Pump & Silent Shaft Assembly. DISASSEMBLY Disassemble front case, oil pump and silent shaft in numbered sequence noting the following: 1. Use oil pressure switch socket No. MD998054 or equivalent to remove oil pressure switch. 2. Remove oil pan, refer to Oil Pan Replacement under Engine Lubrication/Service and Repair. 3. Use plug cap socket No. MD998162 or equivalent to remove front case plug cap (17). Fig. 36 Blocking Silent Shaft For Oil Pump Sprocket Removal 4. When removing oil pump driven gear bolt, insert a Phillips screwdriver into plug hole, to block the silent shaft. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Service and Repair > Page 1385 Fig. 30 Removing Silent Shaft Front Bearings. 5. Using silent shaft bearing puller No. MD998371 or equivalent, remove silent shaft front bearing as shown. Fig. 31 Removing Silent Shaft Rear Bearing. 6. Using silent shaft bearing puller No. MD998372 or equivalent, remove right silent shaft rear bearing as shown. Fig. 37 Removing Left Silent Shaft Rear Bearing. 7. Using silent shaft bearing puller No. MD998374 or equivalent, remove left silent shaft rear bearing as shown. INSPECTION 1. Inspect front case for the following: a. Clogged oil passages. b. Damaged or seized left silent shaft front bearing section. c. Cracks or other signs of damage on case. 2. Inspect oil seal lip for wear or damage, replacing as necessary. 3. Test oil switch as follows: a. Connect an ohmmeter between switch terminal and switch body. b. If ohmmeter reads no continuity, replace switch. If ohmmeter reads continuity, proceed to step c. c. Insert a fine wedge into oil switch hole. Ohmmeter should read no continuity when wedge is slightly pressed into hole, If ohmmeter reads continuity, replace switch. 4. On models with turbocharged engine, inspect oil cooler bypass valve as follows: a. Ensure valves move smoothly. Fig. 38 Oil Cooler Bypass Valve. b. Measure dimension L on bypass valve. At room temperature, dimension L should be 1.358 inch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Service and Repair > Page 1386 c. Dip valve in engine oil heated to 212°F. Dimension L should now be at least 1.570 inch. 5. On all models, inspect oil pump as follows: a. Install oil pump gears in front case and rotate gears, ensuring smooth rotation without excessive looseness. b. Check for for ridge wear on surface of oil pump cover. c. Check drive gear and driven gear tip clearance. d. Check side clearance of gears. 6. Inspect silent shaft for the following: a. Clogged oil passages. b. Seized or damaged journal. c. Ensure oil clearance is within specifications. Clearance should be as follows: Right Front, 0.0008 - 0.0024 inch; Right Rear, 0.0008 - 0.0021 inch; Left Front, 0.0002 - 0.0036 inch; Left Rear, 0.0017 - 0.0033 inch. 7. Inspect oil jet and check valve for clogging or damage. ASSEMBLY Reverse removal procedure to install, noting the following: 1. When installing oil jet, ensure nozzle is installed toward the piston. Fig. 39 Installing Left Silent Shaft Rear Bearing. 2. When installing left silent shaft rear bearing, apply clean engine oil to engine block bearing hole and to outer circumference of bearing. Using bearing installation tool No. MD998374 or equivalent, install bearing into cylinder block. Fig. 40 Installing Right Silent Shaft Rear Bearing. 3. When installing right silent shaft rear bearing, apply clean engine oil to engine block bearing hole and to outer circumference of bearing. Using bearing installation tool No. MD998373 or equivalent, install bearing into cylinder block. Ensure oil hole in bearing is aligned with oil hole in cylinder block. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Service and Repair > Page 1387 Fig. 41 Installing Silent Shaft Front Bearing. 4. When installing silent shaft front bearing, apply clean engine oil to engine block bearing hole and to outer circumference of bearing. Using bearing installation tool No. MD998373 or equivalent, install bearing into cylinder block. Ensure oil hole in bearing is aligned with oil hole in cylinder block. 5. When installing oil pump gears, coat gears with clean engine oil, then align mark on drive gear notch with mark on driven gear tooth. 6. Install crankshaft oil seal using oil seal installation tool No. MD998375 or equivalent. 7. Install oil seal (22) and silent shaft oil seal (23) by placing a socket over the top of the seal and pressing it into the case. Fig. 42 Front Case Attaching Bolts. 8. Install front case as follows: a. Place crankshaft front oil seal guide No. MD998285 or equivalent over front end of crankshaft, then apply engine oil to outer circumference of guide. b. Install front case over top of guide, onto cylinder block. Temporarily tighten all bolts except the filter bracket attaching bolts, referring to bolt length chart. c. Install oil filter bracket and the four attaching bolts. d. Tighten all bolts to specifications. 9. When installing driven gear bolt (19), insert a Phillips screwdriver into plug hole on left side of cylinder block, to block the silent shaft. 10. When installing plug cap, place a new O-ring into groove of case, then use plug cap socket No. MD998162 or equivalent to tighten cap. 11. Install oil pan, refer to Oil Pan Replacement under d12. When installing oil pressure switch, coat threads of switch with gasket adhesive. Do not allow hole in end of switch to be covered with adhesive. Install switch using oil pressure switch socket No. MD998054 or equivalent. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Aluminum Engine - Gasket Surface Preparation Intake Manifold: Technical Service Bulletins Aluminum Engine - Gasket Surface Preparation NO: 09-09-97 GROUP: Engine DATE: Dec. 19, 1997 SUBJECT: Gasket Surface Preparation On Aluminum Engine Components MODELS: 1995 (AA) Acclaim/Spirit 1995 (AJ) Lebaron Convertible 1995 (AS) Caravan/Voyager/Town & Country 1995 - 1998 (FJ) Avenger/Sebring/Talon 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1995 - 1998 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1996 - 1998 (NS) Caravan/Voyager/Town & Country 1995 - 1998 (PL) Neon 1997 (PR) Prowler DISCUSSION: Many aluminum engine components are being received by the material return center with gouges, scratches, and out of flat conditions on the sealing surface. Caution must be exercised when cleaning aluminum engine components. The use of solvents and plastic or wooden scrapers are the only approved methods for removing gasket material. NOTE: DO NOT USE METAL SCRAPERS GRINDING DISCS OR ABRASIVES TO CLEAN ALUMINUM ENGINE COMPONENTS. DAMAGE TO THE SEALING SURFACE WILL OCCUR. Engine components received by the material return center will be evaluated for appropriate gasket removal procedures. Components returned with obvious damage caused by improper gasket removal procedures may be denied for warranty reimbursement. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1392 Intake Manifold: Description and Operation The intake manifold is made of an aluminum alloy, and the shape provides an increased intake inertia effect and has a good volumetric efficiency. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection Intake Manifold: Service and Repair Cleaning and Inspection INTAKE MANIFOLD INSPECTION Check the following points; replace the part if a problem is found: 1. Check for damage or cracking of any part. 2. Check for obstruction of the negative pressure (vacuum) outlet port, and for obstruction of the water passage or gas passage. 3. Using a straight edge and a feeler gauge, check for distortion of the cylinder head installation surface. - Standard value: 0.15 mm (0.006 in) or less - Limit: 0.2 mm (0.008 in.) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1395 Intake Manifold: Service and Repair Intake Manifold Replacement 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. Fig. 1 Fuel Pressure Test Port Fig. 2 Releasing Fuel Pressure FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail (Fig. 1). 4. Place open end of fuel pressure release hose tool No. C-4799-1, or equivalent, into a suitable gasoline container, then connect other hose end to fuel pressure test port. Fuel pressure should bleed off through hose into container. REMOVAL 1. Perform fuel system pressure release procedure before attempting any repairs. 2. Disconnect negative battery cable. 3. Disconnect the fuel supply line quick connect at the fuel tube assembly. WARNING: Wrap shop towels around hose to catch any gasoline spillage. 4. 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 Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1396 Fig. 3 Fresh Air Duct To Throttle Body Assembly 5. Remove fresh air duct and upper air filter housing (Fig. 3) 6. Remove accelerator, kickdown and speed control cables from throttle lever and bracket. Fig. 4 Idle Air Control (IAC) Motor And Throttle Position Sensor (TPS) Wiring Connectors And Vacuum Hose Connection. 7. Disconnect Idle Air Control (IAC) motor and throttle position sensor (TPS) wiring connectors (Fig. 4). 8. Disconnect vacuum hoses from throttle body (Fig. 4). Fig. 5 Intake Manifold Electrical, Vacuum Hose Connections And Knock Sensor Electrical Connector 9. Disconnect Manifold Absolute Pressure (MAP), and intake air temperature electrical connectors. Disconnect vapor and brake booster hoses (Fig. 5). 10. Disconnect knock sensor electrical connector and disconnect wiring harness from tab located on the intake manifold (Fig. 5). 11. Disconnect electrical connector from starter relay. 12. Remove transmission to throttle body support bracket fasteners at the throttle body and loosen fastener at transmission end. 13. Remove throttle body. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1397 Fig. 6 EGR Tube Assembly 14. Remove EGR tube bolts at the valve and at the intake manifold (Fig. 6). Remove tube from engine. Fig. 8 Intake Manifold Tightening Sequence 15. Remove the intake manifold to inlet water tube support fastener (Fig. 8). 16. Remove 9 intake manifold screw and washer assemblies and 1 lock nut. Discard the fasteners. Remove intake manifold. Fig. 7 Intake Manifold O-rings INSPECTION Check for: Inspect manifold for cracks or distortions. - Check for torn or missing O-rings at the mating surface of the manifold (Fig. 7). NOTE: Before installing manifold. Clean all mating surfaces. Replace all seals, with new seals. All intake manifold fasteners and washers are to be discarded and NEW fasteners and washers are to be used. INSTALLATION 1. Install intake manifold onto cylinder head and tighten fasteners to 11.9 N.m (105 in. lbs.) in sequence shown in (Fig. 8). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1398 2. Remove covering from fuel injector holes and insure the holes are clean. Install fuel rail assembly to intake manifold. Tighten screws to 23 N.m (200 in. lbs.). 3. Connect PCV and brake booster hoses (Fig. 5). 4. Inspect quick connect fittings for damage, replace if necessary. Lube tube with clean 30w engine oil, Connect fuel supply hose to fuel rail assembly Check connection by pulling on connector to insure it locked into position. 5. Install throttle body Tighten fastener to 22 N.m (200 in. lbs.). Install transmission to throttle body support bracket and tighten to 11.9 N.m (105 in. lbs.) at the throttle body first. Next tighten the bracket at the transmission. 6. Connect manifold absolute pressure (MAP) and intake air temperature sensor wiring connectors (Fig. 5). 7. Connect knock sensor electrical and starter relay connectors. Connect wiring harness to intake manifold tab. 8. Connect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors (Fig. 4). 9. Connect vacuum hoses to throttle body (Fig. 4). 10. Install accelerator, kickdown and speed control cables to their bracket and connect them to the throttle lever. 11. Loosely assemble the EGR tube onto valve and intake manifold finger tight (Fig. 6). Tighten tube fasteners at the EGR valve first to 11 N.m (95 in. lbs. then, tighten the intake manifold side fasteners to 11 N.m (95 in. lbs.). 12. Install fresh air duct to air filter housing. Tighten clamp to 3 N.m (30 in. lbs.) (Fig. 3). 13. Connect negative battery cable. 14. 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 Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation Fig.3 Gauge LED Locations The fuel, temperature and ammeter gauges are equipped with a Light Emitting Diode (LED) mounted in each of the gauge dials. This diode will illuminate and alert the driver that the system is malfunctioning. The electronic sensor circuit is mounted on the gauge housing. The printed circuit board is permanently attached and is not serviceable. If the LED is malfunctioning, the gauge and the printed circuit board must be replaced as an assembly. The oil pressure warning switch, mounted on the engine, is controlled by engine oil pressure. When engine oil pressure is high (normal operating condition) the switch is held in the Off position allowing no current to flow to the oil pressure warning lamp on the instrument panel. When engine oil pressure is low, the switch is in the On position allowing current to flow to the oil pressure warning lamp on the instrument panel causing the instrument panel to be illuminated. When the switch is in the Off position, it completes the circuit for the electric choke heater. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation CIRCUIT OPERATION The low oil pressure lamp is used to indicate to the operator that the engine oil pressure has dropped below a predetermined pressure. Power for the lamp is provided on the G5 circuit which also powers the other warning lamps. When the oil pressure is low the normally OPEN oil pressure switch CLOSES completing a path to ground. The oil pressure switch is case grounded to the engine block. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Front Cam Seal Retainer - New Design Camshaft Oil Seal: Technical Service Bulletins Front Cam Seal Retainer - New Design NUMBER: 09-008-00 GROUP: Engine DATE: Jan. 12, 2001 SUBJECT: Front Cam Seal Retention OVERVIEW: This bulletin involves installation of a new component to assist cam seal retention. MODELS: NOTE: THIS INFORMATION APPLIES TO MODELS EQUIPPED WITH A 1.8 OR 2.0L SOHC ENGINE. DISCUSSION: A new cam seal retainer has been released to retain the front cam seal on 1.8L or 2.0L SOHC engines. Whenever a cam seal is replaced, a retainer should be installed to provide positive retention. PARTS REQUIRED: REPAIR PROCEDURE: 1. Upon engine re-assembly after front cam seal installation, install the retainer p/n 5016733AA using the inner cover fasteners as shown in (Fig. 1) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal > Component Information > Technical Service Bulletins > Front Cam Seal Retainer - New Design > Page 1411 2. Torque the fasteners to 20 Nm (15 ft. lbs.). 3. Complete the re-assembly following the applicable service manual. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1. With transaxle separated from engine, pry out rear seal with screwdriver. Do not nick or damage crankshaft flange seal surface or retainer bore. 2. Inspect shaft seal surface for nicks or dirt. Polish with 400 grit sandpaper if necessary. 3. Reverse procedure to install, noting the following: a. Seal should be installed dry, with "THIS SIDE OUT" mark facing away from block. b. Use pilot tool No. 6926-1, seal installation tool No. 6926-2 and handle tool No. C-4171, or equivalents, to install seal. Do not drive seal beyond flush with block surface. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Multi Layer Steel Head Gasket - Installation Procedures Technical Service Bulletin # 09-08-99 Date: 990917 Multi Layer Steel Head Gasket - Installation Procedures NUMBER: 09-08-99 GROUP: Engine DATE: Sep. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-05-98, DATED NOV. 6, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE PART NUMBER REVISIONS AND MODEL ADDITIONS. SUBJECT: Multi-Layer Steel (MLS) Head Gasket Installation Procedures MODELS: **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - 2000 (JA) Cirrus/Stratus/Breeze 1996 - 2000 (JX) Sebring Convertible 1995-2000 (PL) Neon 1997 - 2000 (GS) Chrysler Voyager (International Market) NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC (NATURALLY ASPIRATED) OR 2.4L ENGINE. DISCUSSION: Multi-Layer Steel (MLS) head gaskets have been developed and released for use on the above models. The MLS gasket was released for production, as a running change, in the 1999 model year for all models except FJ. This new gasket provides superior sealing characteristics, but will require extra care in their installation where a composite gasket was previously in place. The following steps outline the proper installation of this MLS gasket. CAUTION: ALUMINUM ENGINE COMPONENTS ARE SUSCEPTIBLE TO METAL TRANSFER AND SURFACE DAMAGE WHEN OLD GASKET MATERIAL IS REMOVED FROM THEM. USE EXTREME CARE WHEN CLEANING GASKET MATERIAL FROM ALUMINUM COMPONENTS. THE MLS GASKET CANNOT PROPERLY SEAL IF GOUGING OF SURFACES, METAL TRANSFER, OR COMPOSITE GASKET MATERIAL IS LEFT ON THE HEAD OR BLOCK SURFACES. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Multi Layer Steel Head Gasket - Installation Procedures > Page 1419 PARTS REQUIRED: EQUIPMENT REQUIRED: 1 NPN Plastic/Wooden Scraper AR(1) 07528 2" 3M Roloc Bristle Disc White (For Aluminum Surfaces) AR(1) 07525 2" 3M Roloc Bristle Disc Yellow (For Aluminum/Cast Iron/Steel Surfaces) 1 05539 2" 3M Roloc Bristle Disc Arbor 1 NPN Drill Motor POLICY: Information Only. Repair Procedure This bulletin outlines the proper procedures for preparing head/block surfaces for MLS gasket installation. 1. Following service manual procedures, remove the head. 2. Remove as much of the loose composite gasket material with a plastic or wooden scraper. NOTE: PRIOR TO ADDITIONAL CLEANING, INSPECT THE COOLING PASSAGES OF THE HEAD. REPLACEMENT MAY BE NECESSARY IF EXCESSIVE PITTING OR EROSION HAS TAKEN PLACE THAT WILL COMPROMISE THE SEALING SURFACES AROUND THE COOLING PASSAGES. 3. Cover coolant and oil passages to the best of your ability and apply solvent or a commercially available gasket cleaner to the head/block surfaces. Allow the solvent to soften the remaining composite gasket material. 4. Using a plastic or wooden scraper, scrape the composite gasket residue from the surfaces. If necessary, apply additional solvent or gasket remover to ease removal. 5. If additional cleaning is needed, use a drill motor and 3M Roloc bristle disc p/n 07528 (white) to carefully remove the remaining gasket material from the head and block surfaces. NOTE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Multi Layer Steel Head Gasket - Installation Procedures > Page 1420 IF DIFFICULT TO REMOVE RESIDUE IS LEFT, THE YELLOW ROLOC BRISTLE DISK 3M P/N 07525 CAN BE USED. USE EXTREME CARE WHEN POWER CLEANING ALUMINUM SURFACES TO PREVENT METAL TRANSFER. 6. Inspect the sealing surfaces for any remaining composite gasket residue. Carefully remove any remaining material. 7. The head and block must be checked for flatness. Follow service manual procedures/specifications where applicable. 8. Spray both sides of the MLS gasket with a coat of MOPAR spray gasket sealant p/n 04318035. 9. Re-assemble the engine as outlined in the appropriate service manual. Pay particular attention to head bolt torque and torqueing procedures. All head bolts should be oiled prior to assembly. NOTE: THE 2.0L DOHC TORQUE AND TORQUING PROCEDURE HAS CHANGED WITH THE INSTALLATION OF A MLS GASKET. USE THE FOLLOWING PROCEDURES FOR THE 2.0L DOHC ONLY. 2.OL DOHC TORQUE PROCEDURE WITH MLS GASKET INSTALLATION NOTE: THE 4 SHORT BOLTS ARE PLACED IN THE CORNERS. A. Torque all center bolts to 34 Nm (25 Ft Lbs), Torque the 4 corner bolts to 27 Nm (20 Ft Lbs) see Fig 1 for torque sequence. B. Torque all center bolts to 68 Nm (50 Ft Lbs), Torque the 4 corner bolts to 47 Nm (35 Ft Lbs) see Fig 1 for torque sequence. C. Re-torque all center bolts to 68 Nm (50 Ft Lbs), Re-torque the 4 corner bolts to 47 Nm (35 Ft Lbs) see Fig 1 for torque sequence. D. Tighten all bolts in the specified sequence (Fig 1) an additional 90° (1/4 turn). 10. Make sure the cam sensor seal is replaced on all engine applications. NOTE: A NEW CAM SENSOR SEAL MUST BE INSTALLED DURING THE HEAD GASKET REPLACEMENT PROCEDURE. OIL SEEPAGE FROM THIS SEAL CAN BE MISINTERPRETED AS A HEAD GASKET LEAK. 11. Replace the engine oil and filter after performing these procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Multi Layer Steel Head Gasket - Installation Procedures > Page 1421 Cylinder Head Gasket: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Page 1422 Cylinder Head Gasket: Service and Repair CLEANING Remove all gasket material from cylinder head and block. Be careful not to gouge or scratch the aluminum head sealing surface. For removal and replacement SEE CYLINDER HEAD ASSEMBLY. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Service and Repair Balance Shaft: Service and Repair Fig. 35 Front Case, Oil Pump & Silent Shaft Assembly. DISASSEMBLY Disassemble front case, oil pump and silent shaft in numbered sequence noting the following: 1. Use oil pressure switch socket No. MD998054 or equivalent to remove oil pressure switch. 2. Remove oil pan, refer to Oil Pan Replacement under Engine Lubrication/Service and Repair. 3. Use plug cap socket No. MD998162 or equivalent to remove front case plug cap (17). Fig. 36 Blocking Silent Shaft For Oil Pump Sprocket Removal 4. When removing oil pump driven gear bolt, insert a Phillips screwdriver into plug hole, to block the silent shaft. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Service and Repair > Page 1427 Fig. 30 Removing Silent Shaft Front Bearings. 5. Using silent shaft bearing puller No. MD998371 or equivalent, remove silent shaft front bearing as shown. Fig. 31 Removing Silent Shaft Rear Bearing. 6. Using silent shaft bearing puller No. MD998372 or equivalent, remove right silent shaft rear bearing as shown. Fig. 37 Removing Left Silent Shaft Rear Bearing. 7. Using silent shaft bearing puller No. MD998374 or equivalent, remove left silent shaft rear bearing as shown. INSPECTION 1. Inspect front case for the following: a. Clogged oil passages. b. Damaged or seized left silent shaft front bearing section. c. Cracks or other signs of damage on case. 2. Inspect oil seal lip for wear or damage, replacing as necessary. 3. Test oil switch as follows: a. Connect an ohmmeter between switch terminal and switch body. b. If ohmmeter reads no continuity, replace switch. If ohmmeter reads continuity, proceed to step c. c. Insert a fine wedge into oil switch hole. Ohmmeter should read no continuity when wedge is slightly pressed into hole, If ohmmeter reads continuity, replace switch. 4. On models with turbocharged engine, inspect oil cooler bypass valve as follows: a. Ensure valves move smoothly. Fig. 38 Oil Cooler Bypass Valve. b. Measure dimension L on bypass valve. At room temperature, dimension L should be 1.358 inch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Service and Repair > Page 1428 c. Dip valve in engine oil heated to 212°F. Dimension L should now be at least 1.570 inch. 5. On all models, inspect oil pump as follows: a. Install oil pump gears in front case and rotate gears, ensuring smooth rotation without excessive looseness. b. Check for for ridge wear on surface of oil pump cover. c. Check drive gear and driven gear tip clearance. d. Check side clearance of gears. 6. Inspect silent shaft for the following: a. Clogged oil passages. b. Seized or damaged journal. c. Ensure oil clearance is within specifications. Clearance should be as follows: Right Front, 0.0008 - 0.0024 inch; Right Rear, 0.0008 - 0.0021 inch; Left Front, 0.0002 - 0.0036 inch; Left Rear, 0.0017 - 0.0033 inch. 7. Inspect oil jet and check valve for clogging or damage. ASSEMBLY Reverse removal procedure to install, noting the following: 1. When installing oil jet, ensure nozzle is installed toward the piston. Fig. 39 Installing Left Silent Shaft Rear Bearing. 2. When installing left silent shaft rear bearing, apply clean engine oil to engine block bearing hole and to outer circumference of bearing. Using bearing installation tool No. MD998374 or equivalent, install bearing into cylinder block. Fig. 40 Installing Right Silent Shaft Rear Bearing. 3. When installing right silent shaft rear bearing, apply clean engine oil to engine block bearing hole and to outer circumference of bearing. Using bearing installation tool No. MD998373 or equivalent, install bearing into cylinder block. Ensure oil hole in bearing is aligned with oil hole in cylinder block. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Service and Repair > Page 1429 Fig. 41 Installing Silent Shaft Front Bearing. 4. When installing silent shaft front bearing, apply clean engine oil to engine block bearing hole and to outer circumference of bearing. Using bearing installation tool No. MD998373 or equivalent, install bearing into cylinder block. Ensure oil hole in bearing is aligned with oil hole in cylinder block. 5. When installing oil pump gears, coat gears with clean engine oil, then align mark on drive gear notch with mark on driven gear tooth. 6. Install crankshaft oil seal using oil seal installation tool No. MD998375 or equivalent. 7. Install oil seal (22) and silent shaft oil seal (23) by placing a socket over the top of the seal and pressing it into the case. Fig. 42 Front Case Attaching Bolts. 8. Install front case as follows: a. Place crankshaft front oil seal guide No. MD998285 or equivalent over front end of crankshaft, then apply engine oil to outer circumference of guide. b. Install front case over top of guide, onto cylinder block. Temporarily tighten all bolts except the filter bracket attaching bolts, referring to bolt length chart. c. Install oil filter bracket and the four attaching bolts. d. Tighten all bolts to specifications. 9. When installing driven gear bolt (19), insert a Phillips screwdriver into plug hole on left side of cylinder block, to block the silent shaft. 10. When installing plug cap, place a new O-ring into groove of case, then use plug cap socket No. MD998162 or equivalent to tighten cap. 11. Install oil pan, refer to Oil Pan Replacement under d12. When installing oil pressure switch, coat threads of switch with gasket adhesive. Do not allow hole in end of switch to be covered with adhesive. Install switch using oil pressure switch socket No. MD998054 or equivalent. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Torque Torque Camshaft Sprocket Bolt 85 ft.lb Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Description and Operation Timing Belt: Description and Operation Timing Belt Skipped 1 Tooth or More Trouble Code Name of Code: Timing Belt Skipped 1 Tooth or More When Monitored: With the engine running, every 44ms an inhibit condition is looked for (wide open throttle, large change in rpm, large change in MAP, cold engine, insufficient start to run time, rpm outside given windows). If an inhibit condition does not exist, the misalignment between the camshaft and crankshaft is monitored. Set Condition: When the camshaft position sensor is offset from the crankshaft position sensor one tooth or more. Theory of Operation: The powertrain control module monitors the relationship between two signals, one from the camshaft sensor and one from the crankshaft sensor. If the signals indicate misalignment, a trouble code matures and turns on the malfunction indicator lamp. A misalignment is detected by checking the current alignment against the initial build value stored in the EEPROM of the PCM. This initial build value is established by the PCM when the engine is running in a steady state operating mode. The initial build value is in a reset state at module manufacturing and is set by the PCM. Possible Causes: - Valve timing out of specifications - Camshaft's relative position not relearned (DRB function) after one of the following have been serviced: cam, cam sprocket, timing belt, tensioner, cylinder head, head gasket, crank sprocket, crankshaft, cylinder block or the PCM. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation Timing Belt: Service and Repair Timing Belt Removal and Installation NOTE: With the timing belt removed, avoid turning the camshaft or crankshaft. If movement is required, exercise extreme caution to avoid valve damage caused by piston contact. REMOVAL Fig. 54 Timing Belt Replacement Remove timing belt in numbered sequence as shown, noting the following: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1438 Fig. 55 Crankshaft Pulley Removal 1. Remove crankshaft pulley as shown. 2. Remove power steering pump from the bracket with hose attached and secure out of the way. 3. Place a suitable jack and wood block beneath engine and slightly raise engine to remove engine mount bracket. 4. Align timing marks on camshaft intake and exhaust sprockets before loosening belt tensioner to remove timing belt, Ensure camshaft and crankshaft are not rotated after belt is removed. 5. When belt tensioner is removed, it is necessary to compress the plunger into the tensioner body: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1439 Fig. 57 Timing Belt Tensioner Compression a. Place tensioner in a suitable vise and slowly compress the plunger. b. Index tensioner in vise the same way it is installed on engine to ensure proper pin orientation when installed on engine. c. When plunger is compressed into tensioner body, install a pin through body and plunger to retain plunger in place until tensioner is installed. CAUTION: Do not loosen, remove or tighten tensioner pivot bolt. If this bolt is disturbed, entire pivot bracket assembly must be replaced. INSTALLATION Reverse removal procedure to install noting: Fig. 59 Crankshaft Sprocket Alignment 1. Set the crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing. 2. Using a suitable wrench, move crankshaft to 1/2 notch before TDC. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1440 3. Set the camshaft timing marks by aligning the notches on sprockets. Fig. 60 Timing Belt Installation 4. Install timing belt, starting at crankshaft, around water pump sprocket, idler pulley, camshaft pulleys and tensioner pulley. 5. Move crankshaft sprocket to TDC to take up belt slack. 6. Install belt tensioner to engine block but do not tighten fasteners. 7. Using a suitable torque wrench on the tensioner pulley, torque to 28 ft.-lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1441 Fig. 61 Timing Belt Adjustment 8. With torque being applied to the tensioner pulley, move the tensioner up against the tensioner pulley bracket and torque fasteners to 23 ft.-lbs. 9. Pull the tensioner plunger pin. Pretension is proper when pin can be easily removed or installed. 10. Rotate crankshaft two revolutions and inspect alignment of timing marks. If not proper, repeat procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal and Installation > Page 1442 Timing Belt: Service and Repair Camshaft and Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Technical Service Bulletins > Tensioner Pivot Bracket Assembly - Service Timing Belt Tensioner: Technical Service Bulletins Tensioner Pivot Bracket Assembly - Service NO: 09-06-96 GROUP: Engine DATE: Mar. 29, 1996 SUBJECT: Tensioner Pivot Bracket Assembly Service MODELS: 1995 - 1996 (FJ) Avenger, Sebring, Talon 1995 - 1996 (JA) Cirrus, Stratus, Breeze 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH A 2.0L SOHC OR DOHC ENGINE. DISCUSSION: The following information is in addition to the repair procedure found in the appropriate Service Manual, Group 9, camshaft and crankshaft timing procedure and belt installation section. The tensioner pivot bolt should never be tightened, loosened or removed. The bolt is installed at the manufacturer with a loctite adhesive that is not reusable. If the tensioner pivot bolt is disturbed, the entire pivot bracket assembly (P/N 4777346) must be replaced. See illustration. The pulley fastener that holds the pulley to the pivot bracket may be removed and reinstalled. It should then be torqued to 50 ft. lbs. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Typical -- SOHC Shown Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Curb idle speed ................................................................................................................................... .......................................................... 700 +/- 100 rpm Idle speed when A/C is ON (in neutral) .......... .......................................................................................................................................................... 850 rpm Basic idle speed .................................................................................................................... .......................................................................... 700 +/- 50 rpm NOTE: If these specs differ from the under hood label, then use the information found on the under hood label. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1455 Idle Speed: Testing and Inspection Fig. 31 PCV Vacuum Nipple 1. Turn ignition key off. 2. Disconnect the PCV valve hose from the intake manifold nipple (Fig. 31). Cap the PCV vacuum nipple. Fig. 32 Purge Hose 3. Disconnect purge hose from the nipple on the throttle body (Fig. 32). Fig. 33 Orifice 6457 Attached To Purge Nipple 4. Use a piece of hose to attach Air Metering Orifice 6457 (0.125 in. orifice) or equivalent, to the purge nipple on the throttle body (Fig. 33). 5. Ensure that all accessories are off. 6. Connect the DRB or equivalent scan tool to the data link connector inside the passenger compartment. 7. Run engine in Park or Neutral until the cooling fan has cycled on and off at least once (180°F). 8. Using the DRB or equivalent scan tool, access Minimum Airflow Idle Speed. 9. The following will then occur: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1456 - Idle air control motor will fully close - Idle spark advance will become fixed - PCM will go open loop enriched - DRB or equivalent scan tool displays engine RPM 10. If idle RPM is within the range shown below, throttle body minimum airflow is set correctly. Odometer Reading Idle RPM Below 1,000 Miles 550 - 1,300 RPM Above 1,000 Miles 600 - 1,300 RPM 11. If idle RPM is above specifications, use the DRB or equivalent scan tool to check idle air control motor operation. If idle air control motor is OK, replace throttle body. If idle air flow is below specification, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash thoroughly after using cleaner. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when is closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 14. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 12. Shut off engine. 13. Remove Air Metering Orifice 6457 or equivalent. Install purge hose. 14. Remove cap from PCV valve. Connect hose to PCV valve. 15. Remove DRB or equivalent scan tool. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad Air Cleaner Fresh Air Duct/Hose: Customer Interest Fresh Air Duct - Contacts Hood Insulator Pad NO: 14-05-96 GROUP: Fuel DATE: June 7, 1996 SUBJECT: Wear Marks On Fresh Air Duct And Hood Pad MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES BUILT WITH SPORT/EXPRESSO BUBBLE HOODS AND 2.0L SOHC ENGINES. SYMPTOM/CONDITION: Wear marks on either the fresh air duct or hood pad, due to contact between the two components may be visible. The contact between the fresh air duct and hood pad do not result in a functional problem, but the indentations may be objectional to the customer. PARTS REQUIRED: 1 4669962 Duct, Fresh Air REPAIR PROCEDURE: This bulletin involves the installation of a new fresh air duct which provides additional clearance. 1. Remove the plastic wing nut from the fresh air duct mount. See Illustration. 2. Remove the fresh air duct from the air cleaner box. 3. Install new fresh air duct (P/N 4669962) in the air cleaner box. CAUTION: THE FRESH AIR DUCT MUST BE COMPLETELY SNAPPED INTO THE AIR CLEANER BOX. VERIFY THAT THE DUCT IS FIRMLY IN PLACE. 4. Install the wing nut, while pushing down in the marked area of the fresh air duct. See Illustration. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad > Page 1466 TIME ALLOWANCE: Labor Operation No: 14-10-29-92 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Fresh Air Duct - Contacts Hood Insulator Pad NO: 14-05-96 GROUP: Fuel DATE: June 7, 1996 SUBJECT: Wear Marks On Fresh Air Duct And Hood Pad MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES BUILT WITH SPORT/EXPRESSO BUBBLE HOODS AND 2.0L SOHC ENGINES. SYMPTOM/CONDITION: Wear marks on either the fresh air duct or hood pad, due to contact between the two components may be visible. The contact between the fresh air duct and hood pad do not result in a functional problem, but the indentations may be objectional to the customer. PARTS REQUIRED: 1 4669962 Duct, Fresh Air REPAIR PROCEDURE: This bulletin involves the installation of a new fresh air duct which provides additional clearance. 1. Remove the plastic wing nut from the fresh air duct mount. See Illustration. 2. Remove the fresh air duct from the air cleaner box. 3. Install new fresh air duct (P/N 4669962) in the air cleaner box. CAUTION: THE FRESH AIR DUCT MUST BE COMPLETELY SNAPPED INTO THE AIR CLEANER BOX. VERIFY THAT THE DUCT IS FIRMLY IN PLACE. 4. Install the wing nut, while pushing down in the marked area of the fresh air duct. See Illustration. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad > Page 1472 TIME ALLOWANCE: Labor Operation No: 14-10-29-92 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 050596 > May > 96 > Rear Brakes - Cyclic Chirping Noise Wheel Cylinder: All Technical Service Bulletins Rear Brakes - Cyclic Chirping Noise NO: 05-05-96 GROUP: Brakes DATE: May 5, 1996 SUBJECT: Rear Brake Cyclic Chirp NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-04-96 DATED MARCH 8, 1996 AND TECHNICAL SERVICE BULLETIN 05-06-95 DATED MAY 19, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE 1996 SEBRING CONVERTIBLE HAS BEEN ADDED AND THE "PROTECT -A- CUP", LUBE IS NOW AVAILABLE THRU MOPAR PARTS. ALL CHANGES ARE MARKED WITH **ASTERISKS** MODELS: 1995 - 1996 (PL) Neon 1996 (JX) Sebring Convertible** SYMPTOM/CONDITION: A cyclic chirp noise from the rear of the vehicle during medium to light brake application, at low speeds (20 mph or less) on vehicles equipped with rear drum brakes. The noise can be related to the speed at which the tire turns (one squeak/squawk per revolution of the tire). As the vehicle slows, during the brake application, the noise will occur at a slower rate. **NOTE: THIS REPAIR HAS NO EFFECT ON THE REAR BRAKE HOWL NOISE THAT MAY OCCUR ON NEONS, AT THE END OF THE STOP. THE REAR BRAKE HOWL NOISE IS COVERED IN A SEPARATE TECHNICAL SERVICE BULLETIN.** PARTS REQUIRED: 1 4883068 "Protect -A- Cup" (Lube Cap) REPAIR PROCEDURE: This bulletin involves the installation of 4 drops of the "Protect -A- Cup" lubricant into each rear wheel cylinder. 1. Raise car on suitable hoist and remove rear wheels. 2. Remove rear brake drum retaining clips (1 per side) and remove rear brake drums. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 050596 > May > 96 > Rear Brakes - Cyclic Chirping Noise > Page 1478 3. Peel back the top edge of the wheel cylinder boot and put four drops of the "Protect - A - Cup" fluid into the wheel cylinder. This fluid acts as a lubricant between the wheel cylinder the piston and the wheel cylinder boot (Figure 1). 4. Install the wheel cylinder boot onto the wheel cylinder casting. Make sure that the boot seats properly on the casting lip all the way around the wheel cylinder. 5. Repeat the process for the other three boots (two per brake). CAUTION: THE "PROTECT -A- CUP" ASSEMBLY FLUID USED TO ADDRESS THE CYCLIC CHIRP NOISE SHOULD NOT BE USED FOR ANY PURPOSE IN THE VEHICLE1S BRAKE SYSTEM OTHER THAN AS DESCRIBED IN THIS TSB. 6. Wipe any spilled fluid from the outside of the wheel cylinder as well as any other brake parts including the linings. 7. Install the brake drums, retaining clips and rear wheels. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-90-50-93 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 050596 > May > 96 > Rear Brakes - Cyclic Chirping Noise > Page 1484 3. Peel back the top edge of the wheel cylinder boot and put four drops of the "Protect - A - Cup" fluid into the wheel cylinder. This fluid acts as a lubricant between the wheel cylinder the piston and the wheel cylinder boot (Figure 1). 4. Install the wheel cylinder boot onto the wheel cylinder casting. Make sure that the boot seats properly on the casting lip all the way around the wheel cylinder. 5. Repeat the process for the other three boots (two per brake). CAUTION: THE "PROTECT -A- CUP" ASSEMBLY FLUID USED TO ADDRESS THE CYCLIC CHIRP NOISE SHOULD NOT BE USED FOR ANY PURPOSE IN THE VEHICLE1S BRAKE SYSTEM OTHER THAN AS DESCRIBED IN THIS TSB. 6. Wipe any spilled fluid from the outside of the wheel cylinder as well as any other brake parts including the linings. 7. Install the brake drums, retaining clips and rear wheels. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-90-50-93 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Fig. 104 Air Intake Duct Fig. 105 Removal/Installation of Air Inlet Duct NOTE: Neon vehicles do not use a heated air inlet system. The PCM adjusts fuel injector pulse width and ignition timing to compensate for different ambient temperatures. NOTE: The air cleaner attaches to a bracket on the rear of the cylinder head. An ambient air duct supplies underhood air for the engine. REMOVAL 1. Remove air intake tube (Fig. 104) from air cleaner and intake manifold (Fig. 105). Fig. 106 Removal/Installation Air Cleaner Front Housing and Element 2. Tighten clasps on top of air cleaner housing. Rotate front of housing forward then lift front away from air cleaner housing (Fig 106). 3. Remove air cleaner element from front housing (Fig. 106). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1488 INSTALLATION 1. Install air cleaner element into front housing. 2. Rotate front of housing forward then lower into place and locate tabs in slots. - Fasten clasps on top of air cleaner housing. - Install air intake duct at air cleaner and intake manifold. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1493 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 12 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) 6. Replace Pressure test port cap when finished releasing pressure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications 1995 - 1996 2.0L, 2.4L Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Cable Routing and Firing Order Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum Cables #1 & #4 3,050 Ohms 4,250 Ohms Cables #2 & #3 2,300 Ohms 3,300 Ohms Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1504 Ignition Cable: Description and Operation NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Plastic clips in various locations protect the cables from damage. When the cables are replaced the clips must be used to prevent damage to the cables. The #1 cable must be routed under the PCV hose and clipped to the #2 cable. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Ignition Cable: Initial Inspection and Diagnostic Overview Fig. 3 Spark Plug Cables NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Be sure that the plastic clip on PCV hose is positioned so that cable clip is beneath hose, and that #1 cable is snapped into this clip to protect it from metal PCV clamp. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1507 Ignition Cable: Component Tests and General Diagnostics Testing For Open Circuits, High Resistance and Loose Terminals Use an ohmmeter to check cables for opens, loose terminals or high resistance as follows: 1. Remove cable from spark plug. 2. Remove cable from the coil tower. 3. Connect the ohmmeter between the spark plug end terminal and the coil end terminal. - Make sure ohmmeter probes are in good contact. - Resistance should be within tolerance shown in the cable resistance chart. - If resistance is not within tolerance, replace cable assembly. Test all spark plug cables in the same manner. - If no problems are found, SEE Ignition System/System Diagnosis/Testing For Spark At Coil. SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum Cables #1 & #4 3,050 Ohms 4,250 Ohms Cables #2 & #3 2,300 Ohms 3,300 Ohms Testing For Punctures and Cracks When testing cables for punctures and cracks with an oscilloscope and an inductive voltage probe, follow the instructions of the equipment manufacturers. CAUTION: Do not leave any one spark plug cable disconnected for more than 30 seconds during test or possible heat damage to catalytic converter will occur. If an oscilloscope and inductive probe are not available, cables can be tested as follows: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. WARNING: The ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. 2. With the engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). - If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. - Replace cracked, leaking or faulty cables. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning Ignition Cable: Service and Repair Cleaning Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning > Page 1510 Ignition Cable: Service and Repair Replacement Fig. 3 Spark Plug Cables NOTE: The cables insulate the spark plugs and cover the top of the spark plug tube (Fig. 3). CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. REMOVAL 1. Remove spark plug cable from coil first. Lightly grasp the top of the cable. 2. Rotate the insulator 1/2 turn and pull straight up in a steady motion. 3. To replace the cables, disconnect the cable from the ignition coil. INSTALLATION Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube.Then connect the other end to coil pack. Be sure that the plastic clip on PCV hose is positioned so that cable clip is beneath hose, and that #1 cable is snapped into this clip to protect it from metal PCV clamp. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Spark Plugs - Intermittent Misfire Spark Plug: Technical Service Bulletins Spark Plugs - Intermittent Misfire NO: 18-10-97 GROUP: Vehicle Performance DATE: Feb. 28, 1997 SUBJECT: Intermittent Single Cylinder Misfire And/Or MIL Illuminated THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-15-96 REV. A DATED JULY 12, 1996 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1996 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-97010). ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE SPECIFIC ENGINE APPLICATIONS FOR FJ MODELS. MODELS: 1995 - 1996 (PL) Neon 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH 2.0L SOHC ENGINE (JA & PL), PRIOR TO JANUARY 2, 1996 (MDH 01-02-XX) AND WITH 2.0L DOHC ENGINE (PL) PRIOR TO APRIL 1, 1996 (MDH 04-01-XX) AND TO ALL 1995 & 1996 FJ **NATURALLY ASPIRATED** 2.0L VEHICLES. SYMPTOM/CONDITION: Intermittent single cylinder misfire as indicated by the Diagnostic Trouble Code (DTC) screen on the DRB III which cannot be readily reproduced. DIAGNOSIS: Follow the diagnostic steps in the 1996 Powertrain Diagnostic Manual for 2.0L/2.4L/2.5L/3.3L/3.5L Electronic Fuel Injection (Publication Number 81-699-95008), pages 417 to 419 (Test 107A). If the diagnostic repair procedure does not repair the problem, proceed to the repair procedure. PARTS REQUIRED: NOTE: IT IS IMPERATIVE THAT THE CHRYSLER PART NUMBER GIVEN BELOW BE REQUESTED WHEN ORDERING. ONLY THE CHRYSLER PART NUMBER WAS CHANGED, THE CHAMPION PART NUMBER DID NOT CHANGE. AR 5269897 Spark Plug, (PL & JA - SOHC & DOHC) AR 5269899 Spark Plug, (FJ- DOHC **Naturally Aspirated**) REPAIR PROCEDURE: This bulletin involves the replacement of the spark plug in the effected cylinder with a new spark plug. 1. Remove the spark plug cable. 2. Remove the spark plug and discard. 3. Install the new spark plug and torque to 28 Nm (20 ft. lbs.). 4. Install the spark plug cable. NOTE: THE FOLLOWING STEP IS REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Spark Plugs - Intermittent Misfire > Page 1515 5. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-17-03-91 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications Spark Plug: Specifications Gap Specifications Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap .............................................................................................................................................. ............................................. 0.033 to 0.038 in Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications > Page 1518 Spark Plug: Specifications Tightening Specifications Spark Plugs ......................................................................................................................................... ................................................ 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications > Page 1519 Spark Plug: Specifications Part Number and Thread Size Type - Champion RC9YC Thread size - 14mm (3/4 in) reach Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1520 Spark Plug: Application and ID Type - Champion RC9YC Thread size - 14mm (3/4 in) reach Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1521 Spark Plug: Description and Operation Resistor spark plugs are used in this engine. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for spark plug diagnosis. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1524 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1525 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1526 Spark Plug: Testing and Inspection Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1527 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1528 clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Heavy Colored Deposits DESCRIPTION: Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on the side facing the intake valve. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap, and reinstall .............................................................................................................................................................. .................................................................................... Normal Operating Conditions NORMAL OPERATING CONDITIONS Normal Operation And Cold(Carbon) Fouling The few deposits present will be probably light tan or slightly gray in color with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000 miles) of operation for non Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1529 platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, have the electrodes filed and regapped, and then reinstalled. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum spark plugs. This would damage the platinum pads which would shorten spark plug life. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit. The rust color deposits can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Oil or Ash Encrusted OIL OR ASH ENCRUSTED Oil Or Ash Encrusted If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of spark plugs. Ash encrusted spark plugs can be cleaned and reused. Premature Electrode Wear - Preignition Damage PREIGNITION DAMAGE Preignition Damage Excessive combustion chamber temperature can cause preignition damage. First, the center electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Other possible causes include ignition timing over-advanced and incorrect spark plug heat range. Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1530 center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Determine if the spark plugs are the correct type, as specified on the VECI label, or if other operating conditions are causing engine overheating. Red, Brown, Yellow or White Deposits - Fuel Additives SCAVENGER DEPOSITS Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed using standard procedures. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and reused. Shiny Yellow Glaze COMBUSTION DEPOSITS A shiny yellow glaze coating on the spark plug insulator is evidence of metallic by-products of fuel combustion, caused by chemical additives in certain fuels. Avoid sudden acceleration with wide open throttle after long periods of low speed driving. Spark plugs with combustion deposits can be cleaned and reused. Spark Plug Inspection ^ Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance Schedules. ^ Spark plugs that have low mileage may be cleaned and reused if not otherwise defective -- SEE Spark Plug Condition. After cleaning, file the center electrode flat with a small point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The spark plug gap is 0.033 to0.038 in. ^ Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Wet Oily Deposits FUEL FOULING A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. White or Gray - Burned or Blistered Insulator SPARK PLUG OVERHEATING Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1531 Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in. per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug overheating. Also check for lean air-fuel mixture. Check the torque value of the plugs to ensure good plug-engine seat contact. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1532 Spark Plug: Adjustments Setting Spark Plug Electrode Gap Fig.2 Setting Spark Plug Electrode Gap Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground -- center electrode. Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap .............................................................................................................................................. ............................................. 0.033 to 0.038 in Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1533 Spark Plug: Service and Repair CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. CAUTION: Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. SPARK PLUG REMOVAL 1. Remove the spark plug using a quality socket with a rubber or foam insert. 2. Inspect the spark plug condition. SPARK PLUG CLEANING Spark plugs that have low mileage may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. SPARK PLUG INSTALLATION 1. To avoid cross threading, start the spark plug into the cylinder head by hand. 2. Tighten spark plugs to 28 Nm (20 ft lb) torque. 3. Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube. 4. Connect coil. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Correct compression pressure is 170-225 psi. Compression pressure should not vary more than 25% from cylinder to cylinder. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1537 Compression Check: Testing and Inspection Perform compression test with engine at normal operating temperature, spark plugs removed and throttle wide open. Standard compression pressure is 170-225 psi. The minimum compression pressure is 100 psi with a maximum variation between highest and lowest cylinders of 25 percent. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments Hydraulic lash adjusters are used; no adjustment is necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair Water Pump: Service and Repair REMOVAL 1. Raise vehicle on a hoist. Remove right inner splash shield. 2. Remove accessory drive belts and power steering pump. 3. Drain cooling system. 4. Support engine from the bottom and remove right engine mount. 5. Remove power steering pump bracket bolts and set pump and bracket assembly aside. Power steering lines do not need to be disconnected. 6. Remove right engine mount bracket. 7. Remove timing belt. 8. Remove inner timing belt cover. 9. Remove water pump attaching screws to engine. INSTALLATION 1. Install O-ring in water pump body O-ring groove. Use small dabs of Mopar Silicone Rubber Adhesive Sealant, or equivalent around the water pump body to secure O-ring in place during installation. CAUTION: Make sure O-ring is properly seated in water pump groove before tightening screws. An improperly located O-ring may cause damage to the O-ring and cause a coolant leak. 2. Assemble pump body to block and tighten screws to 12 Nm (105 inch lbs). Pressurize cooling system to 15 psi with pressure tester and check water pump shaft seal and O-ring for leaks. 3. Rotate pump by hand to check for freedom of movement. 4. Install inner timing belt cover. 5. Install timing belt. 6. Install right engine mount bracket and engine mount. 7. Fill cooling system. 8. Install power steering pump and accessory drive belts. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations Coolant: Technical Service Bulletins Engine - Coolant Recommendations NO: 07-03-97 GROUP: Cooling DATE: May 9, 1997 SUBJECT: Engine Coolant Usage THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-05-93 DATED NOV. 26, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1993 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-94000). THE COMPLETE BULLETIN IS REVISED. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1997 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger/ Power Ram/Power Ram Cab & Chassis 1989 - 1993 (AG) Daytona 1989 (AH) Lancer/LeBaron GTS 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1997 (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1997 (BR) Ram Truck 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1989 - 1992 (MJ) Comanche 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1997 (PR) Prowler 1992 - 1997 (SR) Viper/Viper Coupe 1997 (TJ) Wrangler 1989 - 1997 (XJ) Cherokee 1989 - 1995 (YJ) Wrangler 1993 - 1997 (ZJ) Grand Cherokee DISCUSSION: Some owners have expressed interest in using engine coolants made with propylene glycol instead of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals. Based on recent test data, most owners should not experience significant effects on cooling system performance when using propylene glycol based coolant. The use of national brand propylene glycol based engine coolant that meets the same Chrysler ethylene glycol specification of MS-7170 (or equivalent ASTM D5216) is acceptable for Chrysler built vehicles. NOTE: ANTIFREEZE SOLD FOR PROTECTING PLUMBING ETC. (RV ANTIFREEZE) IS NOT A SUITABLE ENGINE COOLANT. However, owners should be discouraged from changing their engine coolant prior to the regularly scheduled maintenance period. Prematurely changing engine coolant unnecessarily adds to the risk of environmental exposure. Sufficient freeze protection for the region should be maintained. However, do not use more than a 55% solution (-35 F, -37 C). Use the chart that accompanies the propylene glycol coolant, since a higher concentration is required to obtain the same freeze points as ethylene glycol coolant. If the temperatures for your region fall below this, use ethylene glycol coolant. Under severe driving conditions (towing a trailer in hot weather etc.) there may be a slight loss in cooling performance. If this is noticed, the system should be changed back to ethylene glycol coolant. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations > Page 1549 The two types of coolant should not be mixed. The standard testers for measuring freeze protection will not provide an accurate reading when this occurs. If the cooling system is changed to propylene glycol, all the ethylene glycol coolant should be removed using an approved cooling system flush procedure. The freeze protection of propylene glycol cannot be measured with a standard cooling system hydrometer. A refractometer or hydrometer calibrated for propylene glycol is the preferred test tool. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Page 1550 Coolant: Specifications Coolant Capacity, Qts. ......................................................................................................................... ............................................................................. 7.4 Radiator Cap Relief Pressure,lbs .................... .............................................................................................................................................................. ...... 16 Thermo. Opening Temp., °F .................................................................................................... ........................................................................................ 195 Fuel Tank, Gals. .................................. .............................................................................................................................................................. .............. 12.5 Engine Oil Refill, Qts. [03] ............................................................................................ ................................................................................................... 4.5 Auto. Transaxle Oil, Qts.[02] ..... .............................................................................................................................................................. ....................... [01] Man. Transaxle Oil, Pts. ....................................................................................... ...................................................................................................... 4.0-4.6 [01] -- Oil change only, 4.0 qts. After overhaul: except fleet models, 8.9 qts., fleet models, 9.2 qts. [02] -- Approximate make final inspection with dipstick. [03] -- Includes oil filter. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating Radiator Cooling Fan Control Module: Customer Interest Engine Cooling Fan - Vehicle Overheating NO: 07-01-97 GROUP: Cooling EFFECTIVE DATE: Mar. 28, 1997 SUBJECT: Vehicle Overheats And/or A/C Inoperative With No MIL Illumination MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Vehicle overheats (cold/warm weather) during stop and go driving or at an extended idle, and/or A/C becomes inoperative with no malfunction indicator light (MIL) illuminated. Radiator fans are not operating. DIAGNOSIS: Visually inspect the RFI connector and RFI filter module for signs of damage. If damage is found proceed to repair procedure. If no damage is found, proceed to cooling system diagnosis in the 1997 Neon Service Manual (Publication Number 81-270-7025) beginning on page 7-8. (See Illustration) PARTS REQUIRED: 1 04897717AA RFI Fan Filter Module 1 04897674AA Connector Package, Radiator Fan Motor REPAIR PROCEDURE: This bulletin involves the replacement of the RFI fan filter module and connector. 1. Record all radio pre-sets. 2. Disconnect the battery cables from the battery and body ground cable from the upper radiator closure panel (near center of car). 3. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Remove and set aside: - radiator-to-battery strut - battery thermo-guard - battery - battery tray - upper radiator mounts 4. Disconnect the left radiator fan motor. Remove and set aside the left radiator fan module assembly (two upper screws). 5. Disconnect the radiator fan motor feed wiring connector from the right fan motor RFI filter assembly (Illustration). 6. Remove the entire right radiator fan module assembly (two screws). Place the fan module assy face-down on a bench. Radiator Fan Motor Connector (On Vehicle): 7. Cut off the existing wiring connector directly behind the insulator and remove about 6 inches of tape. Slip the two fan wires from the convolute Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 1560 tubing. 8. Stagger cut the two wires on the wire harness side approximately 2-1/2" apart. 9. Strip the insulation off the end of each wire on the wire harness approximately 1". 10. Stagger cut the matching wires on the new connector wiring assembly in the opposite order as you did on the vehicle wire harness side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 11. Strip the insulation off the end of each wire on the wire harness approximately 1". 12. Slide a piece of heat shrink tubing onto each wire of the connector wiring. 13. Connect the wire harness end to the connector wire end by twisting the ends together. Be sure to match colors - green to green and black to black. 14. Solder twisted wire ends using rosin core solder. 15. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 16. Slip the wires back into the convolute tubing. Wrap the entire uncovered convolute tubing with tape. RFI Fan Filter Module (On Bench): 17. Cut off the existing right motor wiring from the RFI filter module assy, and remove about four inches of sleeving. Remove the RFI filter assembly from the shroud (two screws) and discard the RFI filter. 18. Stagger cut the two wires from the motor approximately 2-1/2" apart. NOTE: CUT THE WIRES AWAY FROM THE ONE-TO-TWO WIRE SPLICES. 19. Strip an inch of insulation off the end of each wire from the motor. 20. Stagger cut the matching wires on the new RFI filter module wiring harness in the opposite order as you did on the motor wiring side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 21. Strip an inch of insulation off the end of each wire on the new RFI filter module wiring harness. 22. Slide a piece of heat shrink tubing onto each wire of the RFI filter module wiring harness wiring. 23. Connect each RFI filter module wiring harness end to each motor wire end by twisting the ends together. Be sure to match colors - blue to blue and black to black. 24. Solder twisted wire ends using rosin core solder. 25. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 26. Tape the wire harness over splices up to 1-1/2" behind the back of the RFI filter module box. Install the new RFI filter assembly to the shroud (one screw). 27. Reinstall the right radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.) 28. Install the new connector to the right fan motor RFI fan filter module assembly. Push in until the connector snaps into place. Slide the red tab sideways to lock the connector into place. 29. Re-install the left radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.). Route the RFI output wiring to the left fan motor, and install the connector to the left fan motor. Push in until the connector snaps into place. 30. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Install: - upper radiator mounts - battery tray - battery - battery thermo-guard Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 1561 - radiator-to battery strut 31. Re-connect the body ground cable and battery cables. Torque body ground cable screw to 4.0 Nm (35 lb-in.) and battery terminals to 7.2 Nm (65 lb in.). Verify proper fan operation. 32. Reset all radio pre-sets recorded in step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-55-08-90 0.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating Radiator Cooling Fan Control Module: All Technical Service Bulletins Engine Cooling Fan - Vehicle Overheating NO: 07-01-97 GROUP: Cooling EFFECTIVE DATE: Mar. 28, 1997 SUBJECT: Vehicle Overheats And/or A/C Inoperative With No MIL Illumination MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Vehicle overheats (cold/warm weather) during stop and go driving or at an extended idle, and/or A/C becomes inoperative with no malfunction indicator light (MIL) illuminated. Radiator fans are not operating. DIAGNOSIS: Visually inspect the RFI connector and RFI filter module for signs of damage. If damage is found proceed to repair procedure. If no damage is found, proceed to cooling system diagnosis in the 1997 Neon Service Manual (Publication Number 81-270-7025) beginning on page 7-8. (See Illustration) PARTS REQUIRED: 1 04897717AA RFI Fan Filter Module 1 04897674AA Connector Package, Radiator Fan Motor REPAIR PROCEDURE: This bulletin involves the replacement of the RFI fan filter module and connector. 1. Record all radio pre-sets. 2. Disconnect the battery cables from the battery and body ground cable from the upper radiator closure panel (near center of car). 3. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Remove and set aside: - radiator-to-battery strut - battery thermo-guard - battery - battery tray - upper radiator mounts 4. Disconnect the left radiator fan motor. Remove and set aside the left radiator fan module assembly (two upper screws). 5. Disconnect the radiator fan motor feed wiring connector from the right fan motor RFI filter assembly (Illustration). 6. Remove the entire right radiator fan module assembly (two screws). Place the fan module assy face-down on a bench. Radiator Fan Motor Connector (On Vehicle): 7. Cut off the existing wiring connector directly behind the insulator and remove about 6 inches of tape. Slip the two fan wires from the convolute Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 1567 tubing. 8. Stagger cut the two wires on the wire harness side approximately 2-1/2" apart. 9. Strip the insulation off the end of each wire on the wire harness approximately 1". 10. Stagger cut the matching wires on the new connector wiring assembly in the opposite order as you did on the vehicle wire harness side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 11. Strip the insulation off the end of each wire on the wire harness approximately 1". 12. Slide a piece of heat shrink tubing onto each wire of the connector wiring. 13. Connect the wire harness end to the connector wire end by twisting the ends together. Be sure to match colors - green to green and black to black. 14. Solder twisted wire ends using rosin core solder. 15. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 16. Slip the wires back into the convolute tubing. Wrap the entire uncovered convolute tubing with tape. RFI Fan Filter Module (On Bench): 17. Cut off the existing right motor wiring from the RFI filter module assy, and remove about four inches of sleeving. Remove the RFI filter assembly from the shroud (two screws) and discard the RFI filter. 18. Stagger cut the two wires from the motor approximately 2-1/2" apart. NOTE: CUT THE WIRES AWAY FROM THE ONE-TO-TWO WIRE SPLICES. 19. Strip an inch of insulation off the end of each wire from the motor. 20. Stagger cut the matching wires on the new RFI filter module wiring harness in the opposite order as you did on the motor wiring side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 21. Strip an inch of insulation off the end of each wire on the new RFI filter module wiring harness. 22. Slide a piece of heat shrink tubing onto each wire of the RFI filter module wiring harness wiring. 23. Connect each RFI filter module wiring harness end to each motor wire end by twisting the ends together. Be sure to match colors - blue to blue and black to black. 24. Solder twisted wire ends using rosin core solder. 25. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 26. Tape the wire harness over splices up to 1-1/2" behind the back of the RFI filter module box. Install the new RFI filter assembly to the shroud (one screw). 27. Reinstall the right radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.) 28. Install the new connector to the right fan motor RFI fan filter module assembly. Push in until the connector snaps into place. Slide the red tab sideways to lock the connector into place. 29. Re-install the left radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.). Route the RFI output wiring to the left fan motor, and install the connector to the left fan motor. Push in until the connector snaps into place. 30. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Install: - upper radiator mounts - battery tray - battery - battery thermo-guard Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 1568 - radiator-to battery strut 31. Re-connect the body ground cable and battery cables. Torque body ground cable screw to 4.0 Nm (35 lb-in.) and battery terminals to 7.2 Nm (65 lb in.). Verify proper fan operation. 32. Reset all radio pre-sets recorded in step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-55-08-90 0.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Specifications Radiator Cooling Fan Motor: Specifications Fan Motor to Shroud Retaining Screws (A/C Equipped) 3.8 Nm 34 In Lbs Fan Motor to Shroud Retaining Screws (non A/C Equipped) 2.3 Nm 20 In Lbs Fan Module (Shroud) to Radiator Fasteners 7.3 Nm 65 In Lbs Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1574 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1575 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1576 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1577 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1578 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1579 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1580 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1581 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1582 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1583 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1584 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1585 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1586 Radiator Cooling Fan Motor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1587 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1588 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1589 Radiator Cooling Fan Motor: Electrical Diagrams Dual Cooling Fans A/C & Heater System -- Sheet 8w-42-4 Chrysler Does not provide a wiring diagram for dual fans on 95-98 model year Neons. This diagram is for the 99 model year and is presented for reference only. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1590 Air Conditioning/Heater (Part 3 Of 3) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1591 Cooling Fan Modules Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Description and Operation > Circuit Operation Radiator Cooling Fan Motor: Description and Operation Circuit Operation Cooling Fan Modules Circuit Operation The radiator fan system used in this vehicle uses one relay located in the Power Distribution Center (PDC). Power for the coil side of the relay is supplied on circuit F12. This circuit is HOT in the START and RUN position and protected by a 15 Amp fuse located in cavity 10 of the fuse block. Power for the fuse is supplied on circuit A21 from the ignition switch. Power for the A21 circuit is supplied by circuit A1 from the PDC. The A1 circuit is protected by a 30 Amp fuse in the PDC. Power for the contact side of the relay is supplied on circuit A16. This circuit is HOT at all times and protected by a 30 Amp fuse located in the PDC. Ground for the coil side of the relay is controlled by the Powertrain Control Module (PCM). When the PCM determines the need for fan operation the PCM supplies the ground path for circuit C27. This circuit connects to cavity 55 of the PCM connector. This causes the contacts in the relay to CLOSE connecting circuits A16 and C25. The C25 circuit connects to the radiator fan motor. Ground for the motor is supplied on circuit Z1. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Description and Operation > Circuit Operation > Page 1594 Radiator Cooling Fan Motor: Description and Operation Cooling Fan Motor Description Cooling Fan Modules All models use single speed electric motor driven cooling system fan(s). The fan module(s) includes a motor, fan blade, and support shroud. The module is fastened to the radiator by screws. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Description and Operation > Circuit Operation > Page 1595 Radiator Cooling Fan Motor: Description and Operation Radiator Fan Control Cooling Fan Modules Fan control is accomplished in two ways. The fan always runs when the compressor clutch is engaged. - The fan is also turned on by the temperature of the coolant which is sensed by the coolant temperature sensor. The coolant temperature sensor sends this signal to the engine controller which turns the fan on through the fan relay. Switching through the engine controller provides fan control for the following conditions: 1. Fan will not run when cranking engine no matter what coolant temperature is. 2. Fan will run when A/C clutch engaged and low pressure cutout switch is closed. 3. At vehicle speeds over 40 mph, fan will run only if coolant temperature reaches 230°F (110°C) and fan will turn off when temperature drops to 220°F (104°C). 4. At vehicle speeds under 40 mph, fan will run when coolant temperature reaches 215°F (102°C) and fan will turn off when temperature drops 200° F (93°C). 5. To prevent steaming, the fan will run with engine at idle speed and only for three minutes, when ambient temperature is below 60°F (16°C) and coolant temperature is between 100-207°F (38-97°C). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Testing and Inspection > Fan Motor Inoperative Radiator Cooling Fan Motor: Testing and Inspection Fan Motor Inoperative Note: This procedure has been updated by TSB 070197 Dated 03/28/97. Radiator fans are not operating. Visually inspect the RFI connector and RFI filter module for signs of damage. (See Illustration) - If damage is found proceed to RFI Repair Procedure. See: Service and Repair Cooling System Diagnosis - If no damage is found, proceed to cooling system diagnosis. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Testing and Inspection > Fan Motor Inoperative > Page 1598 Radiator Cooling Fan Motor: Testing and Inspection Radiator Fan Motor Disconnect fan motor electrical connector, then connect a 14 gauge jumper wire from battery positive terminal to fan motor terminal. If fan motor does not operate normally, replace fan motor. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Service and Repair > Fan Motor Assembly (Module) Radiator Cooling Fan Motor: Service and Repair Fan Motor Assembly (Module) WARNING: Do not disassemble the fan motor from the support bracket. NOTE: Electric fan motor is serviced as an assembly with the fan module. REMOVAL 1. Disconnect fan motor leads from module. Servicing Fan Module 2. Remove fan module fasteners from radiator. INSTALLATION 1. Install module to radiator. Torque shroud to radiator fasteners to 7.3 Nm (65 inch lbs.). 2. Connect fan motor lead. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Service and Repair > Fan Motor Assembly (Module) > Page 1601 Radiator Cooling Fan Motor: Service and Repair RFI Repair Procedure Note: This procedure has been updated by TSB 070197 Dated 03/28/97. Parts Required: 1 04897717AA RFI Fan Filter Module 1 04897674AA Connector Package, Radiator Fan Motor Repair Procedure: Note: This procedure involves the replacement of the RFI fan filter module and connector. 1. Record all radio pre-sets. 2. Disconnect the battery cables from the battery and body ground cable from the upper radiator closure panel (near center of car). 3. Referring to instructions and following all warnings. Remove and set aside: radiator-to-battery strut - battery thermo-guard - battery - battery tray - upper radiator mounts 4. Disconnect the left radiator fan motor. Remove and set aside the left radiator fan module assembly (two upper screws). 5. Disconnect the radiator fan motor feed wiring connector from the right fan motor RFI filter assembly (Illustration). 6. Remove the entire right radiator fan module assembly (two screws). Place the fan module assembly face-down on a bench. Radiator Fan Motor Connector (On Vehicle): 7. Cut off the existing wiring connector directly behind the insulator and remove about 6 inches of tape. Slip the two fan wires from the convolute tubing. 8. Stagger cut the two wires on the wire harness side approximately 2 1/2 inches apart. 9. Strip the insulation off the end of each wire on the wire harness approximately 1 inch. 10. Stagger cut the matching wires on the new connector wiring assembly in the opposite order as you did on the vehicle wire harness side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 11. Strip the insulation off the end of each wire on the wire harness approximately 1 inch. 12. Slide a piece of heat shrink tubing onto each wire of the connector wiring. 13. Connect the wire harness end to the connector wire end by twisting the ends together. Be sure to match colors - green to green and black to black. 14. Solder twisted wire ends using rosin core solder. 15. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 16. Slip the wires back into the convolute tubing. Wrap the entire uncovered convolute tubing with tape. RFI Fan Filter Module (On Bench): 17. Cut off the existing right motor wiring from the RFI filter module assembly, and remove about four inches of sleeving. Remove the RFI filter assembly from the shroud (two screws) and discard the RFI filter. 18. Stagger cut the two wires from the motor approximately 2 1/2 inches apart. NOTE: Cut the wires away from the one-to-two wire splices. 19. Strip an inch of insulation off the end of each wire from the motor. 20. Stagger cut the matching wires on the new RFI filter module wiring harness in the opposite order as you did on the motor wiring side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 21. Strip an inch of insulation off the end of each wire on the new RFI filter module wiring harness. 22. Slide a piece of heat shrink tubing onto each wire of the RFI filter module wiring harness wiring. 23. Connect each RFI filter module wiring harness end to each motor wire end by twisting the ends together. Be sure to match colors - blue to blue and black to black. 24. Solder twisted wire ends using rosin core solder. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Service and Repair > Fan Motor Assembly (Module) > Page 1602 25. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 26. Tape the wire harness over splices up to 1 1/2 inches behind the back of the RFI filter module box. Install the new RFI filter assembly to the shroud (one screw). 27. Reinstall the right radiator fan module (two screws). Torque to 7.2 Nm (65 In. Lbs.) 28. Install the new connector to the right fan motor RFI fan filter module assembly. Push in until the connector snaps into place. Slide the red tab sideways to lock the connector into place. 29. Re-install the left radiator fan module (two screws). Torque to 7.2 Nm (65 In. Lbs.) Route the RFI output wiring to the left fan motor, and install the connector to the left fan motor. Push in until the connector snaps into place. 30. Referring to instructions and following all warnings. Install: upper radiator mounts - battery tray - battery - battery thermo-guard - radiator-to battery strut 31. Re-connect the body ground cable and battery cables. Torque body ground cable screw to 4.0 Nm (35 In. Lbs.) and battery terminals to 7.2 Nm (65 In. Lbs.). Verify proper fan operation. 32. Reset all radio pre-sets recorded in step 1. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations Radiator Fan Relay: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 1606 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 1607 Solid State Relay Solid State Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions Radiator Fan Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1610 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1611 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1612 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1613 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1614 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1615 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1616 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1617 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1618 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1619 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1620 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1621 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1622 Radiator Fan Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1623 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1624 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1625 Radiator Fan Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1626 Radiator Fan Relay: Electrical Diagrams Dual Cooling Fans A/C & Heater System -- Sheet 8w-42-4 Chrysler Does not provide a wiring diagram for dual fans on 95-98 model year Neons. This diagram is for the 99 model year and is presented for reference only. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1627 Air Conditioning/Heater (Part 3 Of 3) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Description and Operation > Radiator Fan Relay Description Radiator Fan Relay: Description and Operation Radiator Fan Relay Description Radiator Fan Relay-PCM Output The PCM energizes the radiator fan through the radiator fan relay. The PCM controls the ground circuit for the solenoid side of the relay. Buss bars in the Power Distribution Center (PDC) supply voltage to the solenoid side and contact side of the relay. The radiator fan power circuit contains a 30 amp fuse between the buss bar in the PDC and the radiator fan relay. The fuse is located in the PDC. When engine coolant reaches a temperature of 99°C (210°F), the PCM energizes the radiator fan. The PCM turns the fan OFF when coolant temperature drops to 93°C (199°F). Whenever the PCM energizes the A/C compressor clutch it engages the fan. Also, to prevent radiator steaming, the PCM energizes the radiator fan at idle following certain cold starts. The radiator fan relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. See: Diagrams/Connector Views Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Description and Operation > Radiator Fan Relay Description > Page 1630 Radiator Fan Relay: Description and Operation Description of Trouble Codes High Speed Fan Relay Control Circuit Name of Code: High Speed Fan Control Relay Circuit When Monitored: With the ignition key in the run position and battery voltage above 10 volts. Set Condition: An open or shorted condition is detected in the high speed fan relay control circuit. Theory of Operation: The high speed fan relay controls the high speed operation of the radiator fans. The relay is located in the power distribution center. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the run position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay control circuit when the engine coolant temperature is too high and removes the ground when the temperature is acceptable. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - High speed fan relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module Rad Fan Control Relay Circuit Name of Code: Rad Fan Control Relay Circuit When Monitored: With the ignition key on, battery voltage greater than 10 volts, and the PCM requests the fans to be turned on. Set Condition: An open or shorted condition is detected in the Radiator Fan Control Relay Circuit. Theory of Operation: The solid state radiator fan relay controls the operation of the radiator fans. One connector of the relay is supplied with fused B(+) to power the fans. This same B(+) connection powers the internal electronics in the relay. The chassis ground connection (physical attachment to the chassis) on the relay provides a heat sink for the relay and a ground for the internal electronics. The ground connection from the relay connector is a redundant ground for the internal relay electronics. If the relay attachment to the chassis becomes loose or corroded the relay could fail due to its inability to dissipate heat through the chassis attachment. when the relay control circuit is grounded by the PCM, current flows through the relay to the fans. As the engine temperature rises to a preset level, the PCM will start sending a "Pulse Width Modulated" (PWM) ground signal to the relay. The dwell time of the signal will increase or decrease from 30% to 100% based on the engine coolant temperature and A/C pressures. this method of controlling the fans provides an infinitely variable fan speed. Possible Causes: - Relay Failure - Fused B(+) - Radiator fan relay control circuit open or shorted - PCM Failure - Connector terminals - Connector Wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair Fan Blade: Service and Repair The fan blade cannot be repaired in any way. Warpage, cracking or other damage can only be remedied by blade replacement. To remove from motor shaft, proceed as follows: 1. Support motor and shaft. Failure to do so may result in damage from excessive force. 2. Remove retaining clip from front of shaft, then draw fan blade off shaft. It may be necessary to eliminate burrs from shaft prior to blade removal. 3. Reverse procedure to install. Ensure motor and shaft are supported during fan blade retaining clip installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 18 Nm (165 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1638 Engine Coolant Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1639 Engine Coolant Temperature Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1640 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig.13 Engine Coolant Temperature Sensor-DOHC PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the intake manifold next to the thermostat housing (Fig. 13). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine cool and temperature gauge in the instrument cluster on circuit G20. See: Lamps and Indicators - Cooling System/Temperature Gauge/Description and Operation From circuit K2 the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics Coolant Temperature Sensor/Switch (For Computer): Component Tests and General Diagnostics Helpful Information The engine coolant temperature sensor is case grounded. The case ground provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Component Testing Fig. 80 Engine Coolant Temperature Sensor Location-DOHC 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 80). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 1643 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.39 Engine Coolant Temperature Sensor-DOHC NOTE: The engine coolant temperature sensor threads into the rear of the cylinder head. New sensors have sealant applied to the threads. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. - Tighten to 18 Nm (165 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair Heater Hose: Service and Repair CAUTION: When removing hoses from heater core inlet or outlet nipples DO NOT exert excess pressure. The heater core may become damaged and leak engine coolant. NOTE: Review Cooling System Precautions before proceeding with this operation. REMOVAL 1. Drain engine cooling system. 2. Remove clamp at end of heater hose to be removed. Heater Hose Quick Connect 3. ON Right Hand Drive (RHD) vehicles, heater hoses at the heater core connection have quick connects. The quick connect consist of two pieces; a quick connect and insert. The quick connect is removed by compressing the insert with a pliers, and pulling the quick connect free of the insert/nipple. Carefully compressed insert pulling the quick connect from connector nipple. The insert will remain on the connector nipple as the quick connect is removed. 4. Remove the heater hose clamp from the heater hose at the block and remove hose. INSTALLATION NOTE: The insert should be removed from the connector nipple and placed inside of the quick connect before reassembly. For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation CIRCUIT OPERATION The temperature gauge is connected to the engine coolant temperature sensor on the G20 circuit. The engine coolant temperature sensor for the gauge is a combination unit. One side of the unit is used for the Powertrain Control Module (PCM) and the other side for the cluster. The sending unit is case grounded to the engine. The logic driven gauge moves in response to the measured resistance of the engine coolant temperature sending unit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Recalls: > 694 > Oct > 96 > Recall - Radiator Technical Service Bulletin # 694 Date: 961001 Recall - Radiator No. 694 October, 1996 To: All Dodge and Chrysler-Plymouth Dealers Subject: Customer Satisfaction Notification # 694 - Radiator Models: ^ 1996 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) From April 24, 1996 Through May 28, 1996 (MDH 042423 Through MDH 052800) ^ 1996 Model Year Dodge Ram (BR) Trucks Equipped With a 8.0L V-10 or Cummins Diesel Engine ("W" or "C" in the 8th VIN Position) Built at the Lago Alberto Assembly Plant ("M" in the 11th VIN Position) From April 24, 1996 Through May 24, 1996 (MDH 042423 Through MDH 052400) The radiator on the above listed vehicles, may leak due to an improper manufacturing process. To correct this condition, the radiator build date code must be inspected and the radiator must be replaced if necessary. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this notification will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer notification letter and a list of the involved vehicles by first class mail. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. All other dealers: Each Dodge and Chrysler-Plymouth dealer who does not receive a Vehicle List will receive a copy of this dealer notification letter by first class mail. DIAL System Functions 53, 70 and VIP All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of notification mailing for dealer inquiry as needed. Parts Due to the small number of involved vehicles, no parts will be distributed initially to dealers. Parts should only be ordered after inspection determines replacement to be necessary. IMPORTANT: Each vehicle should be inspected before a replacement radiator is ordered. ONLY 35-40% OF INVOLVED VEHICLES ARE EXPECTED TO REQUIRE RADIATOR REPLACEMENT. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Recalls: > 694 > Oct > 96 > Recall - Radiator > Page 1659 Refer to the table for the appropriate radiator assembly. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown. Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete claim processing instructions. Parts Return NOT REQUIRED -- Removed radiators can not be reused and must be destroyed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Recalls: > 694 > Oct > 96 > Recall - Radiator > Page 1660 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Radiator Build Date Code 1. Locate the radiator build date code as shown in Figure 1. 2. ^ If the build date code is 1166 through 1296, the radiator must be replaced. Continue with Section B (PL) or Section C (BR). ^ If the build date code is not in the above range, no further action is necessary. B. Replace Radiator (PL Vehicles) 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 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. 2. Without removing the radiator pressure cap and with the system not under pressure, open the radiator draincock by turning it counterclockwise. 3. After the coolant reserve tank has emptied, remove the radiator pressure cap and continue draining the radiator. Save the coolant for later reuse. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Recalls: > 694 > Oct > 96 > Recall - Radiator > Page 1661 4. Remove engine air inlet duct. 5. Remove the upper radiator hose from the radiator. 6. Disconnect and cap the automatic transmission hoses, if equipped. 7. Remove the radiator to battery strut and body ground wire (Figure 2). 8. For vehicles equipped with a DOHC engine: Remove the battery and battery tray. 9. Disconnect the radiator fan module electrical connector(s). 10. Remove the fan shroud retainers at the top of the shroud (Figure 3). 11. Lift fan shroud up and out of bottom shroud attachment clips. NOTE: For vehicles with the DOHC engine: Remove the left fan first and then remove the right fan. 12. Remove the lower radiator hose. 13. Remove the upper radiator isolator bracket mounting screws (Figure 2). 14. Disconnect the engine block heater wire, if equipped. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Recalls: > 694 > Oct > 96 > Recall - Radiator > Page 1662 15. Remove the air conditioning condenser attaching screws, if equipped (Figure 4), then lean the condenser forward. NOTE: It is not necessary to discharge the air conditioning system to remove the radiator. 16. Lift the radiator from the engine compartment and DESTROY THE RADIATOR BY PUNCTURING SEVERAL OF THE CORES. REMOVED RADIATORS MUST NOT BE REUSED! 17. Transfer the lower radiator isolators from the removed radiator to the new radiator. 18. Slide the new radiator into position behind the radiator support. 19. Attach the air conditioning condenser, if equipped (Figure 4). Tighten the mounting screws to 50 in-lbs (5.4 N.m). 20. Seat the radiator assembly lower rubber isolators into the mounting holes in the lower crossmember. 21. Install the upper radiator isolator mounting bracket screws. Tighten the screws to 65 in-lbs (7.4 N.m). 22. Install the lower radiator hose. Align the hose and position the clamp so it will not interfere with the engine. 23. Connect the automatic transmission hoses, if equipped. Tighten the hose clamps to 35 in-lbs (4 N.m). 24. Slide the cooling fan module into the clips on the lower radiator flange (Figure 3). NOTE: For vehicles equipped with a DOHC engine: Install the right fan module first and then the left fan module. 25. Install the fan module retaining screws and tighten to 50 in-lbs (5.4 N.m). 26. Connect the cooling fan motor electrical connector (s). 27. Install the upper radiator hose. Align the hose and position the clamp so it will not interfere with the engine or the hood. 28. For vehicles equipped with a DOHC engine: Install the battery and battery tray. 29. Connect the negative battery cable. 30. Fill the radiator with the original coolant until full and fill coolant reserve bottle to at least the FULL mark. NOTE: Be careful not to spill coolant on the drive belts or the generator. 31. Operate engine until it reaches normal operating temperature. Check cooling system and automatic transmission for leaks and proper fluid levels. Adjust as necessary. C. Replace Radiator (BR Trucks) 1. With the ignition key in the OFF position, disconnect the battery. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Recalls: > 694 > Oct > 96 > Recall - Radiator > Page 1663 NOTE: Disconnect BOTH negative battery cables on Cummins Diesel Engine equipped trucks. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. For Diesel engine equipped trucks: Remove the nuts that retain the positive battery cable to the top of the radiator then position the positive battery cable toward the rear. 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. 3. Without removing the radiator pressure cap and with the system not under pressure, open the radiator draincock by turning it counterclockwise. 4. After the coolant reserve tank has emptied, remove the radiator pressure cap and continue draining the radiator. Save the coolant for later reuse. 5. Remove the upper radiator hose from the radiator. 6. Disconnect coolant reserve/overflow tank hose from radiator fill neck nipple. 7. For Diesel engine equipped trucks: Remove the coolant reserve/overflow tank from the fan shroud by pulling straight up. 8. Disconnect the remove the washer pump from the windshield washer reservoir tank, then drain and remove the tank. 9. Remove the two metal clips retaining the upper part of the fan shroud to the top of the radiator. 10. Remove the four fan shroud mounting bolts (Figure 5). Move the shroud rearward over the fan blades toward the engine. 11. Remove the lower radiator hose. 12. For 8.0L V10 engine equipped trucks: Disconnect and cap the automatic transmission hoses, if equipped. NOTE: Be careful not to lose the spacer when removing the quick connects. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Recalls: > 694 > Oct > 96 > Recall - Radiator > Page 1664 13. Remove the two upper radiator mounting bolts (Figure 6). 14. Lift the radiator straight up and out of the engine compartment and DESTROY THE RADIATOR BY PUNCTURING SEVERAL OF THE CORES. REMOVED RADIATORS MUST NOT BE REUSED! 15. Transfer the two upper radiator mounting bolt grommets from the removed radiator to the new radiator. 16. Lower the new radiator into position while guiding the two alignment dowels into the lower radiator support. 17. Install the upper radiator mounting bolts. Tighten the screws to 95 in-lbs (11 N.m). 18. Install the fan shroud. Tighten the retaining screws to 50 in-lbs (5.4 N.m). 19. Install the windshield washer reservoir bottle and install the washer pump. 20. Install the upper and lower radiator hoses. Align the hoses and position the clamps so they will not interfere with the engine or the hood. 21. For 8.0L V10 equipped trucks: Connect the automatic transmission hoses, if equipped. 22. Install the metal clips to the top of the fan shroud. 23. Install the coolant reserve/overflow tank hose to the radiator filler neck nipple. 24. For Diesel engine equipped trucks: Install the positive battery cable to the top of the radiator. 25. Connect the negative battery cable(s). 26. Fill the radiator with the original coolant until full and fill coolant reserve bottle to at least the FULL mark. NOTE: Be careful not to spill coolant on the drive belts or the generator. 27. Operate engine until it reaches normal operating temperature. Check cooling system and automatic transmission for leaks and proper fluid levels. Adjust as necessary. Owner Letter CUSTOMER SATISFACTION NOTIFICATION TO INSPECT YOUR RADIATOR AND REPLACE IT IF NECESSARY Dear Neon or Ram Truck Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting owners of some 1996 Dodge and Plymouth Neon vehicles and 1996 Dodge Ram Trucks equipped with a V-10 or Cummins diesel engine, to return them to their dealer for a special service. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Recalls: > 694 > Oct > 96 > Recall - Radiator > Page 1665 The problem is... The radiator on your Neon or Ram Truck (identified on the enclosed form), must be inspected (and replaced if necessary) to prevent the potential for leakage due to an improper manufacturing process. What you must do... ^ You may inspect the radiator yourself to determine if it must be replaced, by following the instructions printed in this bulletin (Inspect Radiator Build Date Code). If the radiator build date code does not fall within the specified range, no further repair action is necessary. Please mark "INSPECTED BY OWNER" on the preaddressed Vehicle Disposition Form portion of the enclosed Owner Recall Notification Form and put it in the mail. No postage is required. ^ If the radiator requires replacement. or if you prefer not to inspect the radiator yourself, simply contact your dealer to schedule a service appointment. If you inspected the radiator and determined that it must be replaced, ask the dealer to order the new radiator before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. What Chrysler and your dealer will do... Chrysler will repair your Neon or Ram Truck free of charge (parts and labor). If you prefer not to inspect the radiator yourself, your dealer will inspect the radiator and replace it if necessary. The inspection will take only a few minutes to complete. If you or your dealer determine that radiator replacement is required, the dealer will order the appropriate part and schedule a service appointment. Radiator replacement will take approximately one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. We're sorry for any inconvenience, but we believe that this special service will help to ensure your continuing satisfaction with your vehicle. Thanks for your attention to this important matter. Inspect Radiator Build Date Code Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Recalls: > 694 > Oct > 96 > Recall - Radiator > Page 1666 1. Locate the radiator build date code as shown in the figure. 2. ^ If the build date code is 1166 through 1296, the radiator must be replaced. Contact your dealer to schedule a service appointment. ^ If the build date code is not in the above range, no further repair action is necessary. Please mark "INSPECTED BY OWNER" on the preaddressed Vehicle Disposition Form portion of the enclosed Owner Recall Notification Form and put it in the mail. No postage is required. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator: > 232497 > May > 97 > Recalls for Radiator: > 694 > Oct > 96 > Recall - Radiator Technical Service Bulletin # 694 Date: 961001 Recall - Radiator No. 694 October, 1996 To: All Dodge and Chrysler-Plymouth Dealers Subject: Customer Satisfaction Notification # 694 - Radiator Models: ^ 1996 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) From April 24, 1996 Through May 28, 1996 (MDH 042423 Through MDH 052800) ^ 1996 Model Year Dodge Ram (BR) Trucks Equipped With a 8.0L V-10 or Cummins Diesel Engine ("W" or "C" in the 8th VIN Position) Built at the Lago Alberto Assembly Plant ("M" in the 11th VIN Position) From April 24, 1996 Through May 24, 1996 (MDH 042423 Through MDH 052400) The radiator on the above listed vehicles, may leak due to an improper manufacturing process. To correct this condition, the radiator build date code must be inspected and the radiator must be replaced if necessary. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this notification will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer notification letter and a list of the involved vehicles by first class mail. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. All other dealers: Each Dodge and Chrysler-Plymouth dealer who does not receive a Vehicle List will receive a copy of this dealer notification letter by first class mail. DIAL System Functions 53, 70 and VIP All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of notification mailing for dealer inquiry as needed. Parts Due to the small number of involved vehicles, no parts will be distributed initially to dealers. Parts should only be ordered after inspection determines replacement to be necessary. IMPORTANT: Each vehicle should be inspected before a replacement radiator is ordered. ONLY 35-40% OF INVOLVED VEHICLES ARE EXPECTED TO REQUIRE RADIATOR REPLACEMENT. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator: > 232497 > May > 97 > Recalls for Radiator: > 694 > Oct > 96 > Recall - Radiator > Page 1676 Refer to the table for the appropriate radiator assembly. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown. Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete claim processing instructions. Parts Return NOT REQUIRED -- Removed radiators can not be reused and must be destroyed. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator: > 232497 > May > 97 > Recalls for Radiator: > 694 > Oct > 96 > Recall - Radiator > Page 1677 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Radiator Build Date Code 1. Locate the radiator build date code as shown in Figure 1. 2. ^ If the build date code is 1166 through 1296, the radiator must be replaced. Continue with Section B (PL) or Section C (BR). ^ If the build date code is not in the above range, no further action is necessary. B. Replace Radiator (PL Vehicles) 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 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. 2. Without removing the radiator pressure cap and with the system not under pressure, open the radiator draincock by turning it counterclockwise. 3. After the coolant reserve tank has emptied, remove the radiator pressure cap and continue draining the radiator. Save the coolant for later reuse. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator: > 232497 > May > 97 > Recalls for Radiator: > 694 > Oct > 96 > Recall - Radiator > Page 1678 4. Remove engine air inlet duct. 5. Remove the upper radiator hose from the radiator. 6. Disconnect and cap the automatic transmission hoses, if equipped. 7. Remove the radiator to battery strut and body ground wire (Figure 2). 8. For vehicles equipped with a DOHC engine: Remove the battery and battery tray. 9. Disconnect the radiator fan module electrical connector(s). 10. Remove the fan shroud retainers at the top of the shroud (Figure 3). 11. Lift fan shroud up and out of bottom shroud attachment clips. NOTE: For vehicles with the DOHC engine: Remove the left fan first and then remove the right fan. 12. Remove the lower radiator hose. 13. Remove the upper radiator isolator bracket mounting screws (Figure 2). 14. Disconnect the engine block heater wire, if equipped. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator: > 232497 > May > 97 > Recalls for Radiator: > 694 > Oct > 96 > Recall - Radiator > Page 1679 15. Remove the air conditioning condenser attaching screws, if equipped (Figure 4), then lean the condenser forward. NOTE: It is not necessary to discharge the air conditioning system to remove the radiator. 16. Lift the radiator from the engine compartment and DESTROY THE RADIATOR BY PUNCTURING SEVERAL OF THE CORES. REMOVED RADIATORS MUST NOT BE REUSED! 17. Transfer the lower radiator isolators from the removed radiator to the new radiator. 18. Slide the new radiator into position behind the radiator support. 19. Attach the air conditioning condenser, if equipped (Figure 4). Tighten the mounting screws to 50 in-lbs (5.4 N.m). 20. Seat the radiator assembly lower rubber isolators into the mounting holes in the lower crossmember. 21. Install the upper radiator isolator mounting bracket screws. Tighten the screws to 65 in-lbs (7.4 N.m). 22. Install the lower radiator hose. Align the hose and position the clamp so it will not interfere with the engine. 23. Connect the automatic transmission hoses, if equipped. Tighten the hose clamps to 35 in-lbs (4 N.m). 24. Slide the cooling fan module into the clips on the lower radiator flange (Figure 3). NOTE: For vehicles equipped with a DOHC engine: Install the right fan module first and then the left fan module. 25. Install the fan module retaining screws and tighten to 50 in-lbs (5.4 N.m). 26. Connect the cooling fan motor electrical connector (s). 27. Install the upper radiator hose. Align the hose and position the clamp so it will not interfere with the engine or the hood. 28. For vehicles equipped with a DOHC engine: Install the battery and battery tray. 29. Connect the negative battery cable. 30. Fill the radiator with the original coolant until full and fill coolant reserve bottle to at least the FULL mark. NOTE: Be careful not to spill coolant on the drive belts or the generator. 31. Operate engine until it reaches normal operating temperature. Check cooling system and automatic transmission for leaks and proper fluid levels. Adjust as necessary. C. Replace Radiator (BR Trucks) 1. With the ignition key in the OFF position, disconnect the battery. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator: > 232497 > May > 97 > Recalls for Radiator: > 694 > Oct > 96 > Recall - Radiator > Page 1680 NOTE: Disconnect BOTH negative battery cables on Cummins Diesel Engine equipped trucks. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. For Diesel engine equipped trucks: Remove the nuts that retain the positive battery cable to the top of the radiator then position the positive battery cable toward the rear. 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. 3. Without removing the radiator pressure cap and with the system not under pressure, open the radiator draincock by turning it counterclockwise. 4. After the coolant reserve tank has emptied, remove the radiator pressure cap and continue draining the radiator. Save the coolant for later reuse. 5. Remove the upper radiator hose from the radiator. 6. Disconnect coolant reserve/overflow tank hose from radiator fill neck nipple. 7. For Diesel engine equipped trucks: Remove the coolant reserve/overflow tank from the fan shroud by pulling straight up. 8. Disconnect the remove the washer pump from the windshield washer reservoir tank, then drain and remove the tank. 9. Remove the two metal clips retaining the upper part of the fan shroud to the top of the radiator. 10. Remove the four fan shroud mounting bolts (Figure 5). Move the shroud rearward over the fan blades toward the engine. 11. Remove the lower radiator hose. 12. For 8.0L V10 engine equipped trucks: Disconnect and cap the automatic transmission hoses, if equipped. NOTE: Be careful not to lose the spacer when removing the quick connects. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator: > 232497 > May > 97 > Recalls for Radiator: > 694 > Oct > 96 > Recall - Radiator > Page 1681 13. Remove the two upper radiator mounting bolts (Figure 6). 14. Lift the radiator straight up and out of the engine compartment and DESTROY THE RADIATOR BY PUNCTURING SEVERAL OF THE CORES. REMOVED RADIATORS MUST NOT BE REUSED! 15. Transfer the two upper radiator mounting bolt grommets from the removed radiator to the new radiator. 16. Lower the new radiator into position while guiding the two alignment dowels into the lower radiator support. 17. Install the upper radiator mounting bolts. Tighten the screws to 95 in-lbs (11 N.m). 18. Install the fan shroud. Tighten the retaining screws to 50 in-lbs (5.4 N.m). 19. Install the windshield washer reservoir bottle and install the washer pump. 20. Install the upper and lower radiator hoses. Align the hoses and position the clamps so they will not interfere with the engine or the hood. 21. For 8.0L V10 equipped trucks: Connect the automatic transmission hoses, if equipped. 22. Install the metal clips to the top of the fan shroud. 23. Install the coolant reserve/overflow tank hose to the radiator filler neck nipple. 24. For Diesel engine equipped trucks: Install the positive battery cable to the top of the radiator. 25. Connect the negative battery cable(s). 26. Fill the radiator with the original coolant until full and fill coolant reserve bottle to at least the FULL mark. NOTE: Be careful not to spill coolant on the drive belts or the generator. 27. Operate engine until it reaches normal operating temperature. Check cooling system and automatic transmission for leaks and proper fluid levels. Adjust as necessary. Owner Letter CUSTOMER SATISFACTION NOTIFICATION TO INSPECT YOUR RADIATOR AND REPLACE IT IF NECESSARY Dear Neon or Ram Truck Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting owners of some 1996 Dodge and Plymouth Neon vehicles and 1996 Dodge Ram Trucks equipped with a V-10 or Cummins diesel engine, to return them to their dealer for a special service. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator: > 232497 > May > 97 > Recalls for Radiator: > 694 > Oct > 96 > Recall - Radiator > Page 1682 The problem is... The radiator on your Neon or Ram Truck (identified on the enclosed form), must be inspected (and replaced if necessary) to prevent the potential for leakage due to an improper manufacturing process. What you must do... ^ You may inspect the radiator yourself to determine if it must be replaced, by following the instructions printed in this bulletin (Inspect Radiator Build Date Code). If the radiator build date code does not fall within the specified range, no further repair action is necessary. Please mark "INSPECTED BY OWNER" on the preaddressed Vehicle Disposition Form portion of the enclosed Owner Recall Notification Form and put it in the mail. No postage is required. ^ If the radiator requires replacement. or if you prefer not to inspect the radiator yourself, simply contact your dealer to schedule a service appointment. If you inspected the radiator and determined that it must be replaced, ask the dealer to order the new radiator before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. What Chrysler and your dealer will do... Chrysler will repair your Neon or Ram Truck free of charge (parts and labor). If you prefer not to inspect the radiator yourself, your dealer will inspect the radiator and replace it if necessary. The inspection will take only a few minutes to complete. If you or your dealer determine that radiator replacement is required, the dealer will order the appropriate part and schedule a service appointment. Radiator replacement will take approximately one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. We're sorry for any inconvenience, but we believe that this special service will help to ensure your continuing satisfaction with your vehicle. Thanks for your attention to this important matter. Inspect Radiator Build Date Code Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator: > 232497 > May > 97 > Recalls for Radiator: > 694 > Oct > 96 > Recall - Radiator > Page 1683 1. Locate the radiator build date code as shown in the figure. 2. ^ If the build date code is 1166 through 1296, the radiator must be replaced. Contact your dealer to schedule a service appointment. ^ If the build date code is not in the above range, no further repair action is necessary. Please mark "INSPECTED BY OWNER" on the preaddressed Vehicle Disposition Form portion of the enclosed Owner Recall Notification Form and put it in the mail. No postage is required. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator: > Page 1684 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 12 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) 6. Replace Pressure test port cap when finished releasing pressure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > System Information > Service Precautions > Page 1687 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 12 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) 6. Replace Pressure test port cap when finished releasing pressure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating Radiator Cooling Fan Control Module: Customer Interest Engine Cooling Fan - Vehicle Overheating NO: 07-01-97 GROUP: Cooling EFFECTIVE DATE: Mar. 28, 1997 SUBJECT: Vehicle Overheats And/or A/C Inoperative With No MIL Illumination MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Vehicle overheats (cold/warm weather) during stop and go driving or at an extended idle, and/or A/C becomes inoperative with no malfunction indicator light (MIL) illuminated. Radiator fans are not operating. DIAGNOSIS: Visually inspect the RFI connector and RFI filter module for signs of damage. If damage is found proceed to repair procedure. If no damage is found, proceed to cooling system diagnosis in the 1997 Neon Service Manual (Publication Number 81-270-7025) beginning on page 7-8. (See Illustration) PARTS REQUIRED: 1 04897717AA RFI Fan Filter Module 1 04897674AA Connector Package, Radiator Fan Motor REPAIR PROCEDURE: This bulletin involves the replacement of the RFI fan filter module and connector. 1. Record all radio pre-sets. 2. Disconnect the battery cables from the battery and body ground cable from the upper radiator closure panel (near center of car). 3. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Remove and set aside: - radiator-to-battery strut - battery thermo-guard - battery - battery tray - upper radiator mounts 4. Disconnect the left radiator fan motor. Remove and set aside the left radiator fan module assembly (two upper screws). 5. Disconnect the radiator fan motor feed wiring connector from the right fan motor RFI filter assembly (Illustration). 6. Remove the entire right radiator fan module assembly (two screws). Place the fan module assy face-down on a bench. Radiator Fan Motor Connector (On Vehicle): 7. Cut off the existing wiring connector directly behind the insulator and remove about 6 inches of tape. Slip the two fan wires from the convolute Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 1697 tubing. 8. Stagger cut the two wires on the wire harness side approximately 2-1/2" apart. 9. Strip the insulation off the end of each wire on the wire harness approximately 1". 10. Stagger cut the matching wires on the new connector wiring assembly in the opposite order as you did on the vehicle wire harness side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 11. Strip the insulation off the end of each wire on the wire harness approximately 1". 12. Slide a piece of heat shrink tubing onto each wire of the connector wiring. 13. Connect the wire harness end to the connector wire end by twisting the ends together. Be sure to match colors - green to green and black to black. 14. Solder twisted wire ends using rosin core solder. 15. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 16. Slip the wires back into the convolute tubing. Wrap the entire uncovered convolute tubing with tape. RFI Fan Filter Module (On Bench): 17. Cut off the existing right motor wiring from the RFI filter module assy, and remove about four inches of sleeving. Remove the RFI filter assembly from the shroud (two screws) and discard the RFI filter. 18. Stagger cut the two wires from the motor approximately 2-1/2" apart. NOTE: CUT THE WIRES AWAY FROM THE ONE-TO-TWO WIRE SPLICES. 19. Strip an inch of insulation off the end of each wire from the motor. 20. Stagger cut the matching wires on the new RFI filter module wiring harness in the opposite order as you did on the motor wiring side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 21. Strip an inch of insulation off the end of each wire on the new RFI filter module wiring harness. 22. Slide a piece of heat shrink tubing onto each wire of the RFI filter module wiring harness wiring. 23. Connect each RFI filter module wiring harness end to each motor wire end by twisting the ends together. Be sure to match colors - blue to blue and black to black. 24. Solder twisted wire ends using rosin core solder. 25. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 26. Tape the wire harness over splices up to 1-1/2" behind the back of the RFI filter module box. Install the new RFI filter assembly to the shroud (one screw). 27. Reinstall the right radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.) 28. Install the new connector to the right fan motor RFI fan filter module assembly. Push in until the connector snaps into place. Slide the red tab sideways to lock the connector into place. 29. Re-install the left radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.). Route the RFI output wiring to the left fan motor, and install the connector to the left fan motor. Push in until the connector snaps into place. 30. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Install: - upper radiator mounts - battery tray - battery - battery thermo-guard Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 1698 - radiator-to battery strut 31. Re-connect the body ground cable and battery cables. Torque body ground cable screw to 4.0 Nm (35 lb-in.) and battery terminals to 7.2 Nm (65 lb in.). Verify proper fan operation. 32. Reset all radio pre-sets recorded in step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-55-08-90 0.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating Radiator Cooling Fan Control Module: All Technical Service Bulletins Engine Cooling Fan - Vehicle Overheating NO: 07-01-97 GROUP: Cooling EFFECTIVE DATE: Mar. 28, 1997 SUBJECT: Vehicle Overheats And/or A/C Inoperative With No MIL Illumination MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Vehicle overheats (cold/warm weather) during stop and go driving or at an extended idle, and/or A/C becomes inoperative with no malfunction indicator light (MIL) illuminated. Radiator fans are not operating. DIAGNOSIS: Visually inspect the RFI connector and RFI filter module for signs of damage. If damage is found proceed to repair procedure. If no damage is found, proceed to cooling system diagnosis in the 1997 Neon Service Manual (Publication Number 81-270-7025) beginning on page 7-8. (See Illustration) PARTS REQUIRED: 1 04897717AA RFI Fan Filter Module 1 04897674AA Connector Package, Radiator Fan Motor REPAIR PROCEDURE: This bulletin involves the replacement of the RFI fan filter module and connector. 1. Record all radio pre-sets. 2. Disconnect the battery cables from the battery and body ground cable from the upper radiator closure panel (near center of car). 3. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Remove and set aside: - radiator-to-battery strut - battery thermo-guard - battery - battery tray - upper radiator mounts 4. Disconnect the left radiator fan motor. Remove and set aside the left radiator fan module assembly (two upper screws). 5. Disconnect the radiator fan motor feed wiring connector from the right fan motor RFI filter assembly (Illustration). 6. Remove the entire right radiator fan module assembly (two screws). Place the fan module assy face-down on a bench. Radiator Fan Motor Connector (On Vehicle): 7. Cut off the existing wiring connector directly behind the insulator and remove about 6 inches of tape. Slip the two fan wires from the convolute Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 1704 tubing. 8. Stagger cut the two wires on the wire harness side approximately 2-1/2" apart. 9. Strip the insulation off the end of each wire on the wire harness approximately 1". 10. Stagger cut the matching wires on the new connector wiring assembly in the opposite order as you did on the vehicle wire harness side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 11. Strip the insulation off the end of each wire on the wire harness approximately 1". 12. Slide a piece of heat shrink tubing onto each wire of the connector wiring. 13. Connect the wire harness end to the connector wire end by twisting the ends together. Be sure to match colors - green to green and black to black. 14. Solder twisted wire ends using rosin core solder. 15. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 16. Slip the wires back into the convolute tubing. Wrap the entire uncovered convolute tubing with tape. RFI Fan Filter Module (On Bench): 17. Cut off the existing right motor wiring from the RFI filter module assy, and remove about four inches of sleeving. Remove the RFI filter assembly from the shroud (two screws) and discard the RFI filter. 18. Stagger cut the two wires from the motor approximately 2-1/2" apart. NOTE: CUT THE WIRES AWAY FROM THE ONE-TO-TWO WIRE SPLICES. 19. Strip an inch of insulation off the end of each wire from the motor. 20. Stagger cut the matching wires on the new RFI filter module wiring harness in the opposite order as you did on the motor wiring side (allowing extra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original. 21. Strip an inch of insulation off the end of each wire on the new RFI filter module wiring harness. 22. Slide a piece of heat shrink tubing onto each wire of the RFI filter module wiring harness wiring. 23. Connect each RFI filter module wiring harness end to each motor wire end by twisting the ends together. Be sure to match colors - blue to blue and black to black. 24. Solder twisted wire ends using rosin core solder. 25. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only. 26. Tape the wire harness over splices up to 1-1/2" behind the back of the RFI filter module box. Install the new RFI filter assembly to the shroud (one screw). 27. Reinstall the right radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.) 28. Install the new connector to the right fan motor RFI fan filter module assembly. Push in until the connector snaps into place. Slide the red tab sideways to lock the connector into place. 29. Re-install the left radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.). Route the RFI output wiring to the left fan motor, and install the connector to the left fan motor. Push in until the connector snaps into place. 30. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Install: - upper radiator mounts - battery tray - battery - battery thermo-guard Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 1705 - radiator-to battery strut 31. Re-connect the body ground cable and battery cables. Torque body ground cable screw to 4.0 Nm (35 lb-in.) and battery terminals to 7.2 Nm (65 lb in.). Verify proper fan operation. 32. Reset all radio pre-sets recorded in step 1. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-55-08-90 0.6 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations Radiator Fan Relay: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 1709 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 1710 Solid State Relay Solid State Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions Radiator Fan Relay: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1713 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1714 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1715 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1716 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1717 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1718 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1719 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1720 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1721 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1722 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1723 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1724 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1725 Radiator Fan Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1726 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1727 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1728 Radiator Fan Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1729 Radiator Fan Relay: Electrical Diagrams Dual Cooling Fans A/C & Heater System -- Sheet 8w-42-4 Chrysler Does not provide a wiring diagram for dual fans on 95-98 model year Neons. This diagram is for the 99 model year and is presented for reference only. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 1730 Air Conditioning/Heater (Part 3 Of 3) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Description and Operation > Radiator Fan Relay Description Radiator Fan Relay: Description and Operation Radiator Fan Relay Description Radiator Fan Relay-PCM Output The PCM energizes the radiator fan through the radiator fan relay. The PCM controls the ground circuit for the solenoid side of the relay. Buss bars in the Power Distribution Center (PDC) supply voltage to the solenoid side and contact side of the relay. The radiator fan power circuit contains a 30 amp fuse between the buss bar in the PDC and the radiator fan relay. The fuse is located in the PDC. When engine coolant reaches a temperature of 99°C (210°F), the PCM energizes the radiator fan. The PCM turns the fan OFF when coolant temperature drops to 93°C (199°F). Whenever the PCM energizes the A/C compressor clutch it engages the fan. Also, to prevent radiator steaming, the PCM energizes the radiator fan at idle following certain cold starts. The radiator fan relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. See: Diagrams/Connector Views Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Description and Operation > Radiator Fan Relay Description > Page 1733 Radiator Fan Relay: Description and Operation Description of Trouble Codes High Speed Fan Relay Control Circuit Name of Code: High Speed Fan Control Relay Circuit When Monitored: With the ignition key in the run position and battery voltage above 10 volts. Set Condition: An open or shorted condition is detected in the high speed fan relay control circuit. Theory of Operation: The high speed fan relay controls the high speed operation of the radiator fans. The relay is located in the power distribution center. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the run position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay control circuit when the engine coolant temperature is too high and removes the ground when the temperature is acceptable. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - High speed fan relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module Rad Fan Control Relay Circuit Name of Code: Rad Fan Control Relay Circuit When Monitored: With the ignition key on, battery voltage greater than 10 volts, and the PCM requests the fans to be turned on. Set Condition: An open or shorted condition is detected in the Radiator Fan Control Relay Circuit. Theory of Operation: The solid state radiator fan relay controls the operation of the radiator fans. One connector of the relay is supplied with fused B(+) to power the fans. This same B(+) connection powers the internal electronics in the relay. The chassis ground connection (physical attachment to the chassis) on the relay provides a heat sink for the relay and a ground for the internal electronics. The ground connection from the relay connector is a redundant ground for the internal relay electronics. If the relay attachment to the chassis becomes loose or corroded the relay could fail due to its inability to dissipate heat through the chassis attachment. when the relay control circuit is grounded by the PCM, current flows through the relay to the fans. As the engine temperature rises to a preset level, the PCM will start sending a "Pulse Width Modulated" (PWM) ground signal to the relay. The dwell time of the signal will increase or decrease from 30% to 100% based on the engine coolant temperature and A/C pressures. this method of controlling the fans provides an infinitely variable fan speed. Possible Causes: - Relay Failure - Fused B(+) - Radiator fan relay control circuit open or shorted - PCM Failure - Connector terminals - Connector Wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 18 Nm (165 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1739 Engine Coolant Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1740 Engine Coolant Temperature Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1741 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig.13 Engine Coolant Temperature Sensor-DOHC PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the intake manifold next to the thermostat housing (Fig. 13). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine cool and temperature gauge in the instrument cluster on circuit G20. See: Lamps and Indicators - Cooling System/Temperature Gauge/Description and Operation From circuit K2 the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics Coolant Temperature Sensor/Switch (For Computer): Component Tests and General Diagnostics Helpful Information The engine coolant temperature sensor is case grounded. The case ground provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Component Testing Fig. 80 Engine Coolant Temperature Sensor Location-DOHC 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 80). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 1744 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.39 Engine Coolant Temperature Sensor-DOHC NOTE: The engine coolant temperature sensor threads into the rear of the cylinder head. New sensors have sealant applied to the threads. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. - Tighten to 18 Nm (165 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation CIRCUIT OPERATION The temperature gauge is connected to the engine coolant temperature sensor on the G20 circuit. The engine coolant temperature sensor for the gauge is a combination unit. One side of the unit is used for the Powertrain Control Module (PCM) and the other side for the cluster. The sending unit is case grounded to the engine. The logic driven gauge moves in response to the measured resistance of the engine coolant temperature sending unit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair Thermostat: Service and Repair REMOVAL 1. Drain cooling system to the thermostat level or below. 2. Remove Coolant Recovery System (CRS) hose and thermostat/engine outlet connector bolts. 3. Remove thermostat assembly, and clean sealing surfaces. INSTALLATION 1. Place the new thermostat assembly into the engine outlet connector. Align air bleed with notch on the cylinder head. 2. Install thermostat housing/outlet connector onto cylinder head and tighten bolts to 12.5 Nm (110 inch lbs.). Connect the CRS hose. 3. Refill cooling system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair Water Pump: Service and Repair REMOVAL 1. Raise vehicle on a hoist. Remove right inner splash shield. 2. Remove accessory drive belts and power steering pump. 3. Drain cooling system. 4. Support engine from the bottom and remove right engine mount. 5. Remove power steering pump bracket bolts and set pump and bracket assembly aside. Power steering lines do not need to be disconnected. 6. Remove right engine mount bracket. 7. Remove timing belt. 8. Remove inner timing belt cover. 9. Remove water pump attaching screws to engine. INSTALLATION 1. Install O-ring in water pump body O-ring groove. Use small dabs of Mopar Silicone Rubber Adhesive Sealant, or equivalent around the water pump body to secure O-ring in place during installation. CAUTION: Make sure O-ring is properly seated in water pump groove before tightening screws. An improperly located O-ring may cause damage to the O-ring and cause a coolant leak. 2. Assemble pump body to block and tighten screws to 12 Nm (105 inch lbs). Pressurize cooling system to 15 psi with pressure tester and check water pump shaft seal and O-ring for leaks. 3. Rotate pump by hand to check for freedom of movement. 4. Install inner timing belt cover. 5. Install timing belt. 6. Install right engine mount bracket and engine mount. 7. Fill cooling system. 8. Install power steering pump and accessory drive belts. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Description and Operation Catalyst Shield: Description and Operation CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. PURPOSE The heat shield is needed to protect both the car and the environment from the high temperatures developed in the vicinity of the catalytic converter. CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shield on cars. Light over-spray near the edges is permitted. Application of coating will greatly reduce the efficiency of the heat shields resulting in excessive floor pan temperatures and objectionable fumes. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Mounting Bolts 23 Nm Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 11-02-98 > Feb > 98 > Exhaust System - Noise/Vibration Technical Service Bulletin # 11-02-98 Date: 980206 Exhaust System - Noise/Vibration NO: 11-02-98 GROUP: Exhaust DATE: Feb. 6, 1998 SUBJECT: Excessive Exhaust Noise/Vibration During/After Underbody Contact With Moisture THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-04-96 DATED JUNE 26, 1996 WHICH SHOULD BE NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-97010). A NEW HEAT SHIELD AND REPAIR PROCEDURE ARE PROVIDED IF ALIGNMENT CANNOT BE ACCOMPLISHED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Excessive exhaust noise and/or vehicle vibration during/after vehicle is driven through puddles or underbody contact with snow/slush. The intermediate pipe may be contacting the tunnel heat shield when it is cooled from the water/snow contact. CAUTION: TO PREVENT SERIOUS INJURY FROM HOT EXHAUST COMPONENTS, ENSURE THAT THE VEHICLE HAS NOT BEEN DRIVEN AND THE EXHAUST IS COLD BEFORE INSPECTION AND REPAIR. DIAGNOSIS: With the vehicle on a suitable hoist, inspect the tunnel heat shield for any marks where the intermediate pipe has made contact. If the pipe or heat shield show signs of contact, or the pipe appears to be out of alignment with the tunnel, proceed to the repair procedure. PARTS REQUIRED: AR 04495951 Isolator, Exhaust Rubber **AR 05278028AB Heat Shield** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 11-50-05-95 0.3 Hrs. Exhaust, Re-align and Replace Isolator if Required 11-50-05-96 0.3 Hrs. Exhaust, Re-align and Replace Isolator and Heat Shield FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves aligning the exhaust pipe in the tunnel and straightening the tunnel heat shield. 1. Measure the clearance between the intermediate ("I") pipe and shield/floor pan in the areas of contact. Record this data on the repair order for future use. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 11-02-98 > Feb > 98 > Exhaust System - Noise/Vibration > Page 1770 2. Inspect the catalyst assembly to ensure that the alignment button is fitted into the notch on the "I" pipe (Figure 1). 3. If the alignment button is fitted into the notch and the "I" pipe is not in the center of the tunnel, remove the alignment button to allow centering of the "I" pipe in the tunnel by the following procedure: ^ Separate the "I" pipe from the portion of the pipe with the alignment button. ^ Using a grinder or chisel, remove the alignment button to allow the pipe to turn easily within the "I" pipe. 4. Inspect the rubber isolators on the "I" pipe and muffler for side to side movement, by pushing on the pipe. The rubber isolators are designed for forward and rearward movement only. If the exhaust system cannot be centered as described in steps 2 and 3, replace the rubber isolator with P/N 04495951. 5. If the "I" pipe is correctly aligned down the center of the tunnel and still contacts the heat shield, the heat shield must be replaced. **6. Remove the rear three bolts of the heat shield (Figure 2). 7. Loosen the front two bolts and slide the heat shield off (Figure 2). 8. Slide the new heat shield (P/N 05278028AB) into place over the two front bolts. Ensure that the heat shield is fully seated on the two bolts. 9. Install the rear center bolt and torque to 3.7 N.m (33 in.-lb.). 10. Torque the two front bolts to 3.7 N.m (33 in.-lb.). 11. Install the remaining two rear bolts and torque to 3.7 N.m (33 in.-lb.). 12. Install the intermediate pipe, if removed, and torque clamps to 74.5 N.m (55 ft.lb.). 13. Test drive the vehicle and listen for the noise/vibration. If the noise/vibration is still apparent, proceed to step 14. If the noise/vibration is gone, no Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 11-02-98 > Feb > 98 > Exhaust System - Noise/Vibration > Page 1771 further action is needed.** 14. Inspect the areas of contact and bend the shield to provide more clearance: ^ Measure between the "I" pipe and the heat shield in the areas showing contact marks, there should be a minimum clearance of 25 mm (Figure 3). In the areas that are out of specification, use a pair of pliers to bend the heat shield to provide the proper clearance (Figure 3). ^ Measure between the heat shield and the floor pan in the areas showing contact marks, there should be a minimum of 5 mm clearance (Figure 3). ^ In the areas that are out of specification, use a pair of pliers to bend the heat shield to provide the proper clearance (Figure 3). CAUTION: DO NOT BEND THE HEAT SHIELD TO THE EXTENT THAT IT CONTACTS THE BODY OR BECOMES LOOSE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 11-02-98 > Feb > 98 > Exhaust System - Noise/Vibration Technical Service Bulletin # 11-02-98 Date: 980206 Exhaust System - Noise/Vibration NO: 11-02-98 GROUP: Exhaust DATE: Feb. 6, 1998 SUBJECT: Excessive Exhaust Noise/Vibration During/After Underbody Contact With Moisture THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-04-96 DATED JUNE 26, 1996 WHICH SHOULD BE NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-97010). A NEW HEAT SHIELD AND REPAIR PROCEDURE ARE PROVIDED IF ALIGNMENT CANNOT BE ACCOMPLISHED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Excessive exhaust noise and/or vehicle vibration during/after vehicle is driven through puddles or underbody contact with snow/slush. The intermediate pipe may be contacting the tunnel heat shield when it is cooled from the water/snow contact. CAUTION: TO PREVENT SERIOUS INJURY FROM HOT EXHAUST COMPONENTS, ENSURE THAT THE VEHICLE HAS NOT BEEN DRIVEN AND THE EXHAUST IS COLD BEFORE INSPECTION AND REPAIR. DIAGNOSIS: With the vehicle on a suitable hoist, inspect the tunnel heat shield for any marks where the intermediate pipe has made contact. If the pipe or heat shield show signs of contact, or the pipe appears to be out of alignment with the tunnel, proceed to the repair procedure. PARTS REQUIRED: AR 04495951 Isolator, Exhaust Rubber **AR 05278028AB Heat Shield** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 11-50-05-95 0.3 Hrs. Exhaust, Re-align and Replace Isolator if Required 11-50-05-96 0.3 Hrs. Exhaust, Re-align and Replace Isolator and Heat Shield FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves aligning the exhaust pipe in the tunnel and straightening the tunnel heat shield. 1. Measure the clearance between the intermediate ("I") pipe and shield/floor pan in the areas of contact. Record this data on the repair order for future use. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 11-02-98 > Feb > 98 > Exhaust System - Noise/Vibration > Page 1777 2. Inspect the catalyst assembly to ensure that the alignment button is fitted into the notch on the "I" pipe (Figure 1). 3. If the alignment button is fitted into the notch and the "I" pipe is not in the center of the tunnel, remove the alignment button to allow centering of the "I" pipe in the tunnel by the following procedure: ^ Separate the "I" pipe from the portion of the pipe with the alignment button. ^ Using a grinder or chisel, remove the alignment button to allow the pipe to turn easily within the "I" pipe. 4. Inspect the rubber isolators on the "I" pipe and muffler for side to side movement, by pushing on the pipe. The rubber isolators are designed for forward and rearward movement only. If the exhaust system cannot be centered as described in steps 2 and 3, replace the rubber isolator with P/N 04495951. 5. If the "I" pipe is correctly aligned down the center of the tunnel and still contacts the heat shield, the heat shield must be replaced. **6. Remove the rear three bolts of the heat shield (Figure 2). 7. Loosen the front two bolts and slide the heat shield off (Figure 2). 8. Slide the new heat shield (P/N 05278028AB) into place over the two front bolts. Ensure that the heat shield is fully seated on the two bolts. 9. Install the rear center bolt and torque to 3.7 N.m (33 in.-lb.). 10. Torque the two front bolts to 3.7 N.m (33 in.-lb.). 11. Install the remaining two rear bolts and torque to 3.7 N.m (33 in.-lb.). 12. Install the intermediate pipe, if removed, and torque clamps to 74.5 N.m (55 ft.lb.). 13. Test drive the vehicle and listen for the noise/vibration. If the noise/vibration is still apparent, proceed to step 14. If the noise/vibration is gone, no Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 11-02-98 > Feb > 98 > Exhaust System - Noise/Vibration > Page 1778 further action is needed.** 14. Inspect the areas of contact and bend the shield to provide more clearance: ^ Measure between the "I" pipe and the heat shield in the areas showing contact marks, there should be a minimum clearance of 25 mm (Figure 3). In the areas that are out of specification, use a pair of pliers to bend the heat shield to provide the proper clearance (Figure 3). ^ Measure between the heat shield and the floor pan in the areas showing contact marks, there should be a minimum of 5 mm clearance (Figure 3). ^ In the areas that are out of specification, use a pair of pliers to bend the heat shield to provide the proper clearance (Figure 3). CAUTION: DO NOT BEND THE HEAT SHIELD TO THE EXTENT THAT IT CONTACTS THE BODY OR BECOMES LOOSE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 11-02-98 > Feb > 98 > Exhaust System Noise/Vibration Technical Service Bulletin # 11-02-98 Date: 980206 Exhaust System - Noise/Vibration NO: 11-02-98 GROUP: Exhaust DATE: Feb. 6, 1998 SUBJECT: Excessive Exhaust Noise/Vibration During/After Underbody Contact With Moisture THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-04-96 DATED JUNE 26, 1996 WHICH SHOULD BE NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-97010). A NEW HEAT SHIELD AND REPAIR PROCEDURE ARE PROVIDED IF ALIGNMENT CANNOT BE ACCOMPLISHED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Excessive exhaust noise and/or vehicle vibration during/after vehicle is driven through puddles or underbody contact with snow/slush. The intermediate pipe may be contacting the tunnel heat shield when it is cooled from the water/snow contact. CAUTION: TO PREVENT SERIOUS INJURY FROM HOT EXHAUST COMPONENTS, ENSURE THAT THE VEHICLE HAS NOT BEEN DRIVEN AND THE EXHAUST IS COLD BEFORE INSPECTION AND REPAIR. DIAGNOSIS: With the vehicle on a suitable hoist, inspect the tunnel heat shield for any marks where the intermediate pipe has made contact. If the pipe or heat shield show signs of contact, or the pipe appears to be out of alignment with the tunnel, proceed to the repair procedure. PARTS REQUIRED: AR 04495951 Isolator, Exhaust Rubber **AR 05278028AB Heat Shield** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 11-50-05-95 0.3 Hrs. Exhaust, Re-align and Replace Isolator if Required 11-50-05-96 0.3 Hrs. Exhaust, Re-align and Replace Isolator and Heat Shield FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves aligning the exhaust pipe in the tunnel and straightening the tunnel heat shield. 1. Measure the clearance between the intermediate ("I") pipe and shield/floor pan in the areas of contact. Record this data on the repair order for future use. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 11-02-98 > Feb > 98 > Exhaust System Noise/Vibration > Page 1787 2. Inspect the catalyst assembly to ensure that the alignment button is fitted into the notch on the "I" pipe (Figure 1). 3. If the alignment button is fitted into the notch and the "I" pipe is not in the center of the tunnel, remove the alignment button to allow centering of the "I" pipe in the tunnel by the following procedure: ^ Separate the "I" pipe from the portion of the pipe with the alignment button. ^ Using a grinder or chisel, remove the alignment button to allow the pipe to turn easily within the "I" pipe. 4. Inspect the rubber isolators on the "I" pipe and muffler for side to side movement, by pushing on the pipe. The rubber isolators are designed for forward and rearward movement only. If the exhaust system cannot be centered as described in steps 2 and 3, replace the rubber isolator with P/N 04495951. 5. If the "I" pipe is correctly aligned down the center of the tunnel and still contacts the heat shield, the heat shield must be replaced. **6. Remove the rear three bolts of the heat shield (Figure 2). 7. Loosen the front two bolts and slide the heat shield off (Figure 2). 8. Slide the new heat shield (P/N 05278028AB) into place over the two front bolts. Ensure that the heat shield is fully seated on the two bolts. 9. Install the rear center bolt and torque to 3.7 N.m (33 in.-lb.). 10. Torque the two front bolts to 3.7 N.m (33 in.-lb.). 11. Install the remaining two rear bolts and torque to 3.7 N.m (33 in.-lb.). 12. Install the intermediate pipe, if removed, and torque clamps to 74.5 N.m (55 ft.lb.). 13. Test drive the vehicle and listen for the noise/vibration. If the noise/vibration is still apparent, proceed to step 14. If the noise/vibration is gone, no Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 11-02-98 > Feb > 98 > Exhaust System Noise/Vibration > Page 1788 further action is needed.** 14. Inspect the areas of contact and bend the shield to provide more clearance: ^ Measure between the "I" pipe and the heat shield in the areas showing contact marks, there should be a minimum clearance of 25 mm (Figure 3). In the areas that are out of specification, use a pair of pliers to bend the heat shield to provide the proper clearance (Figure 3). ^ Measure between the heat shield and the floor pan in the areas showing contact marks, there should be a minimum of 5 mm clearance (Figure 3). ^ In the areas that are out of specification, use a pair of pliers to bend the heat shield to provide the proper clearance (Figure 3). CAUTION: DO NOT BEND THE HEAT SHIELD TO THE EXTENT THAT IT CONTACTS THE BODY OR BECOMES LOOSE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 11-02-98 > Feb > 98 > Exhaust System - Noise/Vibration Technical Service Bulletin # 11-02-98 Date: 980206 Exhaust System - Noise/Vibration NO: 11-02-98 GROUP: Exhaust DATE: Feb. 6, 1998 SUBJECT: Excessive Exhaust Noise/Vibration During/After Underbody Contact With Moisture THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-04-96 DATED JUNE 26, 1996 WHICH SHOULD BE NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-97010). A NEW HEAT SHIELD AND REPAIR PROCEDURE ARE PROVIDED IF ALIGNMENT CANNOT BE ACCOMPLISHED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Excessive exhaust noise and/or vehicle vibration during/after vehicle is driven through puddles or underbody contact with snow/slush. The intermediate pipe may be contacting the tunnel heat shield when it is cooled from the water/snow contact. CAUTION: TO PREVENT SERIOUS INJURY FROM HOT EXHAUST COMPONENTS, ENSURE THAT THE VEHICLE HAS NOT BEEN DRIVEN AND THE EXHAUST IS COLD BEFORE INSPECTION AND REPAIR. DIAGNOSIS: With the vehicle on a suitable hoist, inspect the tunnel heat shield for any marks where the intermediate pipe has made contact. If the pipe or heat shield show signs of contact, or the pipe appears to be out of alignment with the tunnel, proceed to the repair procedure. PARTS REQUIRED: AR 04495951 Isolator, Exhaust Rubber **AR 05278028AB Heat Shield** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 11-50-05-95 0.3 Hrs. Exhaust, Re-align and Replace Isolator if Required 11-50-05-96 0.3 Hrs. Exhaust, Re-align and Replace Isolator and Heat Shield FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves aligning the exhaust pipe in the tunnel and straightening the tunnel heat shield. 1. Measure the clearance between the intermediate ("I") pipe and shield/floor pan in the areas of contact. Record this data on the repair order for future use. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 11-02-98 > Feb > 98 > Exhaust System - Noise/Vibration > Page 1794 2. Inspect the catalyst assembly to ensure that the alignment button is fitted into the notch on the "I" pipe (Figure 1). 3. If the alignment button is fitted into the notch and the "I" pipe is not in the center of the tunnel, remove the alignment button to allow centering of the "I" pipe in the tunnel by the following procedure: ^ Separate the "I" pipe from the portion of the pipe with the alignment button. ^ Using a grinder or chisel, remove the alignment button to allow the pipe to turn easily within the "I" pipe. 4. Inspect the rubber isolators on the "I" pipe and muffler for side to side movement, by pushing on the pipe. The rubber isolators are designed for forward and rearward movement only. If the exhaust system cannot be centered as described in steps 2 and 3, replace the rubber isolator with P/N 04495951. 5. If the "I" pipe is correctly aligned down the center of the tunnel and still contacts the heat shield, the heat shield must be replaced. **6. Remove the rear three bolts of the heat shield (Figure 2). 7. Loosen the front two bolts and slide the heat shield off (Figure 2). 8. Slide the new heat shield (P/N 05278028AB) into place over the two front bolts. Ensure that the heat shield is fully seated on the two bolts. 9. Install the rear center bolt and torque to 3.7 N.m (33 in.-lb.). 10. Torque the two front bolts to 3.7 N.m (33 in.-lb.). 11. Install the remaining two rear bolts and torque to 3.7 N.m (33 in.-lb.). 12. Install the intermediate pipe, if removed, and torque clamps to 74.5 N.m (55 ft.lb.). 13. Test drive the vehicle and listen for the noise/vibration. If the noise/vibration is still apparent, proceed to step 14. If the noise/vibration is gone, no Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 11-02-98 > Feb > 98 > Exhaust System - Noise/Vibration > Page 1795 further action is needed.** 14. Inspect the areas of contact and bend the shield to provide more clearance: ^ Measure between the "I" pipe and the heat shield in the areas showing contact marks, there should be a minimum clearance of 25 mm (Figure 3). In the areas that are out of specification, use a pair of pliers to bend the heat shield to provide the proper clearance (Figure 3). ^ Measure between the heat shield and the floor pan in the areas showing contact marks, there should be a minimum of 5 mm clearance (Figure 3). ^ In the areas that are out of specification, use a pair of pliers to bend the heat shield to provide the proper clearance (Figure 3). CAUTION: DO NOT BEND THE HEAT SHIELD TO THE EXTENT THAT IT CONTACTS THE BODY OR BECOMES LOOSE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Customer Interest for Powertrain Control Module: > 18-005-01 > Feb > 01 > PCM - OBDII Readiness Code Retention Powertrain Control Module: Customer Interest PCM - OBDII Readiness Code Retention NUMBER: 18-005-01 GROUP: Vehicle Performance DATE: Feb. 16, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-18-97, DATED MAY 9, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: OBDII Readiness Code Retention OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module. MODELS: 1995-1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (LH) Intrepid/Vision/Concorde/LHS 1996 (PL) Neon NOTE: THIS INFORMATION APPLIES TO FEDERAL EMISSION (SALES CODE NAA) AND CALIFORNIA EMISSION (SALES CODE NAE) MODELS BUILT PRIOR TO NOV. 21, 1995 (MDH1121XX) AND ALL 1995 JA MODELS EQUIPPED WITH A 2.0L ENGINE AND MANUAL TRANSAXLE. THE CALIFORNIA EMISSION MODELS ADDRESSED IN THIS BULLETIN WERE SOLD IN THE NORTHEAST STATES. CALIFORNIA MODELS SOLD IN CALIFORNIA WERE ADDRESSED WITH RECALL 678 DATED SEPT. 1996. DISCUSSION: The On Board Diagnostic (OBDII) system includes a monitor called readiness codes. The readiness codes indicate that all OBDII diagnostic tests have been performed and that diagnostic trouble codes (DTC's) can be read. It has been determined that the readiness codes may be cleared upon ignition key "OFF" cycles. Absence of readiness codes may cause owners to fail their emission inspection. To correct this condition, the Powertrain Control Module (PCM) must be reprogrammed. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING WITH CIS CD2075 OR HIGHER 1. Flash the PCM using the MDS2 (Mopar Diagnostic System) and DRBIII(R) (Scan Tool). NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Customer Interest for Powertrain Control Module: > 18-005-01 > Feb > 01 > PCM - OBDII Readiness Code Retention > Page 1807 2. Type the necessary information on the Authorized Software Update Label p/n 04669020 (Fig. 1). Attach the label to the PCM and cover it 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: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Customer Interest for Powertrain Control Module: > 180696 > Feb > 96 > PCM MIL ON/DTC's 84, 81, 27/9D Set Powertrain Control Module: Customer Interest PCM - MIL ON/DTC's 84, 81, 27/9D Set NO: 18-06-96 GROUP: Vehicle Performance DATE: Feb. 23, 1996 SUBJECT: Malfunction Indicator Light illuminated For Erroneous Hex DTC's 84, 81, 27 And/Or 9D MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 2.0L SOHC AND DOHC ENGINES (AUTOMATIC AND MANUAL TRANSAXLE) BUILT PRIOR TO NOVEMBER 14, 1995 (MDH 11-14-XX) IN THE BELVEDERE ASSEMBLY PLANT (D IN THE 11TH POSITION OF THE VIN) AND NOVEMBER 17, 1995 (MDH 11-17-XX) IN THE TOLUCA ASSEMBLY PLANT (T IN THE 11TH POSITION OF THE VIN). SYMPTOM/CONDITION: The Malfunction Indicator Light (MIL) will be illuminated and the following hex codes (DTC's) may be erroneously set: ^ 84 - TPS voltage does not agree with MAP. ^ 81 - Downstream 02 sensor stays at center. ^ 27 - No change in MAP from start to run. ^ 9D - Intermittent loss of cam or crank position. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If one of the above fault codes are set, verify proper operation as follows: ^ 84 - With key on and engine off, TPS voltage should increase smoothly from less than 1.0 volt at idle to greater than 3.0 volts at WOT. ^ 81 - Rear O2 signal - With the engine warmed up, verify that the rear O2 sensor voltage will read outside the .35 to .65 volt range during a road test, especially during hard deceleration and WOT. ^ 27 - MAP - With key on, check BARO; then start vehicle, verify that vacuum is greater than 4 inches of vacuum. ^ 9D - Cam & Crank - Verify cam and crank are in sync using the DRB III. If the above proper operation is not verified, proceed with the appropriate diagnosis and repair as stated in the Powertrain Diagnostic Procedures Manual prior to performing the software reflash contained in this bulletin. If the above proper operation is verified, proceed with the repair procedure. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 19 OR HIGHER AND TIL CD RELEASE 1099 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves reprogramming (flashing) the PCM with new software (calibrations). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Customer Interest for Powertrain Control Module: > 180696 > Feb > 96 > PCM MIL ON/DTC's 84, 81, 27/9D Set > Page 1812 5. Use the arrow keys and select PROGRAM VEHICLE CONTROLLER on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-44-95 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-005-01 > Feb > 01 > PCM - OBDII Readiness Code Retention Powertrain Control Module: All Technical Service Bulletins PCM - OBDII Readiness Code Retention NUMBER: 18-005-01 GROUP: Vehicle Performance DATE: Feb. 16, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-18-97, DATED MAY 9, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: OBDII Readiness Code Retention OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module. MODELS: 1995-1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (LH) Intrepid/Vision/Concorde/LHS 1996 (PL) Neon NOTE: THIS INFORMATION APPLIES TO FEDERAL EMISSION (SALES CODE NAA) AND CALIFORNIA EMISSION (SALES CODE NAE) MODELS BUILT PRIOR TO NOV. 21, 1995 (MDH1121XX) AND ALL 1995 JA MODELS EQUIPPED WITH A 2.0L ENGINE AND MANUAL TRANSAXLE. THE CALIFORNIA EMISSION MODELS ADDRESSED IN THIS BULLETIN WERE SOLD IN THE NORTHEAST STATES. CALIFORNIA MODELS SOLD IN CALIFORNIA WERE ADDRESSED WITH RECALL 678 DATED SEPT. 1996. DISCUSSION: The On Board Diagnostic (OBDII) system includes a monitor called readiness codes. The readiness codes indicate that all OBDII diagnostic tests have been performed and that diagnostic trouble codes (DTC's) can be read. It has been determined that the readiness codes may be cleared upon ignition key "OFF" cycles. Absence of readiness codes may cause owners to fail their emission inspection. To correct this condition, the Powertrain Control Module (PCM) must be reprogrammed. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING WITH CIS CD2075 OR HIGHER 1. Flash the PCM using the MDS2 (Mopar Diagnostic System) and DRBIII(R) (Scan Tool). NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-005-01 > Feb > 01 > PCM - OBDII Readiness Code Retention > Page 1818 2. Type the necessary information on the Authorized Software Update Label p/n 04669020 (Fig. 1). Attach the label to the PCM and cover it 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: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 180696 > Feb > 96 > PCM - MIL ON/DTC's 84, 81, 27/9D Set Powertrain Control Module: All Technical Service Bulletins PCM - MIL ON/DTC's 84, 81, 27/9D Set NO: 18-06-96 GROUP: Vehicle Performance DATE: Feb. 23, 1996 SUBJECT: Malfunction Indicator Light illuminated For Erroneous Hex DTC's 84, 81, 27 And/Or 9D MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 2.0L SOHC AND DOHC ENGINES (AUTOMATIC AND MANUAL TRANSAXLE) BUILT PRIOR TO NOVEMBER 14, 1995 (MDH 11-14-XX) IN THE BELVEDERE ASSEMBLY PLANT (D IN THE 11TH POSITION OF THE VIN) AND NOVEMBER 17, 1995 (MDH 11-17-XX) IN THE TOLUCA ASSEMBLY PLANT (T IN THE 11TH POSITION OF THE VIN). SYMPTOM/CONDITION: The Malfunction Indicator Light (MIL) will be illuminated and the following hex codes (DTC's) may be erroneously set: ^ 84 - TPS voltage does not agree with MAP. ^ 81 - Downstream 02 sensor stays at center. ^ 27 - No change in MAP from start to run. ^ 9D - Intermittent loss of cam or crank position. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If one of the above fault codes are set, verify proper operation as follows: ^ 84 - With key on and engine off, TPS voltage should increase smoothly from less than 1.0 volt at idle to greater than 3.0 volts at WOT. ^ 81 - Rear O2 signal - With the engine warmed up, verify that the rear O2 sensor voltage will read outside the .35 to .65 volt range during a road test, especially during hard deceleration and WOT. ^ 27 - MAP - With key on, check BARO; then start vehicle, verify that vacuum is greater than 4 inches of vacuum. ^ 9D - Cam & Crank - Verify cam and crank are in sync using the DRB III. If the above proper operation is not verified, proceed with the appropriate diagnosis and repair as stated in the Powertrain Diagnostic Procedures Manual prior to performing the software reflash contained in this bulletin. If the above proper operation is verified, proceed with the repair procedure. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 19 OR HIGHER AND TIL CD RELEASE 1099 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves reprogramming (flashing) the PCM with new software (calibrations). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 180696 > Feb > 96 > PCM - MIL ON/DTC's 84, 81, 27/9D Set > Page 1823 5. Use the arrow keys and select PROGRAM VEHICLE CONTROLLER on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-44-95 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1824 Powertrain Control Module: Specifications PCM 60-Way Connector Torque = 4 Nm (35 in lb) PCM Mounting Screws = 4 Nm (35 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1825 Fig. 100 Powertrain Control Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1828 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1829 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1830 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1831 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1832 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1833 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1834 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1835 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1836 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1837 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1838 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1839 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1840 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1841 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1842 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1843 Powertrain Control Module: Connector Views Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1844 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1845 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1846 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1847 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1848 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1849 Powertrain Control Module: Service Precautions - Before disconnecting any control module, make sure the ignition is off. Failure to do so could damage the module. - When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. - Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. - Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. - Operation of any type, including idling, should be avoided if engine misfiring occurs. Under this condition, the exhaust system operates at abnormally high temperature, which may cause damage to the catalyst or under-body parts of the vehicle. - Alteration or deterioration of ignition or fuel system, or any type of operating condition which results in engine misfiring must be corrected to avoid overheating the catalytic converter. - Proper maintenance and tune-up, according to manufacturer's specifications, should be made to correct abnormal conditions as soon as possible. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation Powertrain Control Module: Description and Operation Circuit Operation CIRCUIT OPERATION Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to cavity 46 of the Powertrain Control Module (PCM). A 20 Amp fuse in the PDC protects circuit A14. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 1852 Powertrain Control Module: Description and Operation PCM Operation Fig. 100 Powertrain Control Module Fig. 3 Data Link Connector The Powertrain Control Module (PCM) is a digital computer containing a microprocessor (Fig. 2). The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. PCM Inputs: Air Conditioning Controls - Battery Voltage - Battery Temperature Sensor - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Fuel Level Sensor - Ignition Switch (A21) - Intake Air Temperature Sensor - Knock Sensor - Manifold Absolute Pressure (MAP) Sensor - Oxygen Sensors - Power Steering Pressure Switch - SCI Receiver - Speed Control Switches - Throttle Position Sensor - Transmission Park/Neutral Switch (Automatic Transmission) - Vehicle Speed Sensor PCM Outputs: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 1853 - Air Conditioning Clutch Relay - Air Conditioning WOT Relay - Auto Shutdown (ASD) Relay - Charging Indicator Lamp - Data Link Connector - Duty Cycle EVAP Canister Purge Solenoid - EGR Solenoid - Fuel Injectors - Fuel Pump Relay - Generator Field - Idle Air Control Motor - Ignition Coils - Malfunction Indicator (Check Engine) Lamp - Radiator Fan Relay - Speed Control Solenoids - Tachometer - Torque Convertor Clutch Solenoid Based on inputs it receives, the PCM adjusts: Fuel Injector Pulse Width - Idle Speed - Ignition Spark Advance - Ignition Coil Dwell - EVAP Canister Purge Operation. The PCM Regulates: Cooling Fan - Air Conditioning - Speed Control System - Generator Charge Rate -- by Adjusting The Generator Field The PCM Also Performs Diagnostics The PCM adjusts injector pulse width (air-fuel ratio) based on: Battery Voltage - Coolant Temperature - Exhaust Gas Content (Oxygen Sensor) - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Manifold Absolute Pressure - Throttle Position The PCM adjusts ignition timing based on: Coolant Temperature - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Knock Sensor - Manifold Absolute Pressure - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) The PCM also adjusts engine idle speed through the idle air control motor based on: Air Conditioning Sense - Battery Temperature - Battery Voltage - Brake Switch - Coolant Temperature - Engine Speed (crankshaft Position Sensor) - Engine Run Time - Manifold Absolute Pressure - Power Steering Pressure Switch - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) - Vehicle Distance (Speed) ASD and Fuel Pump Relay Control Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 1854 The Auto Shutdown (ASD) and fuel pump relays are mounted externally, but turned on and off by the PCM. Crankshaft Position (Engine Speed) Signal The crankshaft position sensor signal is sent to the PCM. If the PCM does not receive the signal within approximately one second of engine cranking, it deactivates the ASD relay and fuel pump relay When these relays deactivate, power is shut off from the fuel injectors, ignition coils, heating element in the oxygen sensors and the fuel pump. PCM Regulated Output Supply Voltages The PCM contains a voltage converter that changes battery voltage to a regulated 8 volts direct current to power: Camshaft Position Sensor - Crankshaft Position Sensor - Vehicle Speed Sensor The PCM also provides a 5 volt direct current supply for: Manifold Absolute Pressure Sensor - Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 1855 Powertrain Control Module: Description and Operation PCM Related Trouble Code Messages Internal Controller Failure WHEN MONITORED With the ignition ON SET CONDITION There is an EPROM sum check failure at power down. THEORY OF OPERATION This code indicates the EPROM memory may be corrupt. PROBABLE CAUSES - Failed PCM PCM Failure EEPROM Write Denied Unsuccessful attempt to write to an EEPROM location by the PCM. PCM Failure SPI Communications WHEN MONITORED With the ignition ON. SET CONDITION Serial communications inside the controller fail eight times. THEORY OF OPERATION Communication between the microprocessors inside the PCM is needed to operate the total system. - A failure to communicate may cause improper actuation of the solenoids and relays. PROBABLE CAUSES - PCM failure PCM Failure SRI Mile Not Stored Unsuccessful attempt to update EMR mileage in the PCM EEPROM. 5 Volt Supply Output Too Low Name of Code: 5-Volt Supply Output Too Low When Monitored: With the ignition on. Set Condition: The 5-volt supply to the sensors is below 3.5 volts for 4 seconds. Theory of Operation: The powertrain control module maintains a 5-volt supply to the MAP sensor, TP sensor, and A/C pressure sensor. It is critical that the 5-volt supply stays between 4.8 volts and 5.1 volts as this input has a direct effect on the sensors' output voltages. Possible Causes: - Shorted 5-volt supply - Shorted sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview Circuit A14 connects to a bus bar in the PDC that the battery feeds. Circuit A14 powers the Automatic Shut Down (ASD) relay and fuel pump relay The A14 circuit also splices to the data link connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1858 Powertrain Control Module: Component Tests and General Diagnostics Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Page 1859 Powertrain Control Module: Service and Repair Fig. 100 Powertrain Control Module NOTE: The PCM attaches to the inner fender panel next to the washer fluid bottle on the driver side (Fig. 100). REMOVAL 1. Disconnect negative cable from battery 2. Disconnect positive cable from battery. 3. Remove washer bottle neck. 4. Squeeze tabs on Power Distribution Center (PDC) while pulling PDC up to remove it from bracket. - Lay PDC aside to gain access to PCM bracket screws. 5. Remove screws attaching PCM to body. 3. Lift PCM up and disconnect the 2 40-way connector 7. Remove PCM. INSTALLATION 1. Attach the 2 40-way connector to PCM. 2. Install PCM. Tighten mounting screws to 4 Nm (35 in lb) torque. 3. Install PDC by pushing down into brackets. 4. Install washer bottle neck. 5. Connect positive cable to battery. 6. Connect negative cable to battery. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig. 15 Power Distribution Center (PDC) Auto Shutdown Relay The relay is located in the Power Distribution Center (PDC) (Fig. 15). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1863 Auto Shutdown Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Automatic Shut Down Relay Automatic Shut Down (ASD) Relay: Description and Operation Automatic Shut Down Relay Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. CIRCUIT OPERATION The Automatic Shut Down (ASD) relay is located in the Power Distribution Center (PDC). Power for the coil and contact side of the relay is supplied on circuit A14. This circuit is HOT at all times and protected by a 20 Amp fuse located in the PDC. The Powertrain Control Module (PCM) controls the ground path for the coil side of the relay on circuit K51. This circuit connects to cavity 67 of the PCM. When the PCM supplies the ground path on circuit K51 the contacts in the relay CLOSE connecting circuits A14 and A142. The A142 circuit is spliced and supplies power to the generator, fuel injectors, PCM, ignition coil, and heated oxygen sensors. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Automatic Shut Down Relay > Page 1866 Automatic Shut Down (ASD) Relay: Description and Operation Related Trouble Codes and Set Conditions Auto Shutdown Relay Control Circuit Name of Code: Auto Shutdown Relay Control Circuit When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: An open or shorted condition is detected in the auto shutdown relay control circuit. Theory of Operation: The automatic shutdown relay (ASD) controls the 12 volt source to the fuel injectors, ignition coil(s), oxygen sensors, and the generator. The relay is located in the power distribution center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the run position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the run or crank position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the ASD relay control circuit ground. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - Auto shutdown relay control circuit open or shorted - Inoperative circuit driver in powertrain control module - PCM failure - Connector terminals - Connector wires No ASD Relay Output Sensed at PCM Name of Code: No Auto Shutdown (ASD) Relay Output Voltage At PCM When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: No voltage sensed at the powertrain control module when the auto shutdown relay is energized. Theory of Operation: When the ASD relay is energized, the relay contacts connect the fused B(+) circuit to the relay output circuit. The powertrain control module is connected in parallel with the ASD relay output circuit. This connection provides the PCM with a circuit to monitor the ASD relay output state. Whenever the PCM energizes the ASD relay, it checks the feedback circuit to ensure voltage is present at the ASD relay output. If voltage is not present, a trouble code is set. Possible Causes: - ASD relay output circuit open - Fused B(+) circuit open - ASD relay - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 Amp fuse located in the PDC. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 1869 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 1870 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 1871 Automatic Shut Down (ASD) Relay: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 Fuel Pump Relay Fig. 15 Power Distribution Center (PDC) The fuel pump relay is located in the Power Distribution Center (PDC). The inside top of the PDC cover has a label showing relay and fuse location. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1876 Fuel Pump Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Fuel Pump Relay Operation Fuel Pump Relay: Description and Operation Fuel Pump Relay Operation NAME OF CODE: Fuel Pump Relay Control Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the fuel pump relay control circuit. THEORY OF OPERATION: The fuel pump relay controls the 12-volt source to the fuel pump. If the vehicle is equipped with a power distribution center, the relay is located in the Power Distribution Center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the RUN or CRANK position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the fuel pump relay control circuit ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Fuel pump relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Fuel Pump Relay Operation > Page 1879 Fuel Pump Relay: Description and Operation Fuel Pump Relay Control Circuit Trouble Code Name of Code: Fuel Pump Relay Control Circuit When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: An open or shorted condition is detected in the fuel pump relay control circuit. Theory of Operation: The fuel pump relay controls the 12-volt source to the fuel pump. If the vehicle is equipped with a power distribution center, the relay is located in the PDC. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "run position". The circuit is completed when the other side of the relay coil is grounded by the powertrain control module. The PCM grounds the relay when the ignition switch is in either the run or crank position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the fuel pump relay control circuit ground. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - Fuel pump relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Page 1880 Fuel Pump Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30 is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85 -- The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86 supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A -- When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87 When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Page 1881 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Complete testing for this system or component can be found at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig. 15 Power Distribution Center (PDC) Auto Shutdown Relay The relay is located in the Power Distribution Center (PDC) (Fig. 15). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1885 Auto Shutdown Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Automatic Shut Down Relay Automatic Shut Down (ASD) Relay: Description and Operation Automatic Shut Down Relay Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. CIRCUIT OPERATION The Automatic Shut Down (ASD) relay is located in the Power Distribution Center (PDC). Power for the coil and contact side of the relay is supplied on circuit A14. This circuit is HOT at all times and protected by a 20 Amp fuse located in the PDC. The Powertrain Control Module (PCM) controls the ground path for the coil side of the relay on circuit K51. This circuit connects to cavity 67 of the PCM. When the PCM supplies the ground path on circuit K51 the contacts in the relay CLOSE connecting circuits A14 and A142. The A142 circuit is spliced and supplies power to the generator, fuel injectors, PCM, ignition coil, and heated oxygen sensors. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Automatic Shut Down Relay > Page 1888 Automatic Shut Down (ASD) Relay: Description and Operation Related Trouble Codes and Set Conditions Auto Shutdown Relay Control Circuit Name of Code: Auto Shutdown Relay Control Circuit When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: An open or shorted condition is detected in the auto shutdown relay control circuit. Theory of Operation: The automatic shutdown relay (ASD) controls the 12 volt source to the fuel injectors, ignition coil(s), oxygen sensors, and the generator. The relay is located in the power distribution center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the run position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the run or crank position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the ASD relay control circuit ground. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - Auto shutdown relay control circuit open or shorted - Inoperative circuit driver in powertrain control module - PCM failure - Connector terminals - Connector wires No ASD Relay Output Sensed at PCM Name of Code: No Auto Shutdown (ASD) Relay Output Voltage At PCM When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: No voltage sensed at the powertrain control module when the auto shutdown relay is energized. Theory of Operation: When the ASD relay is energized, the relay contacts connect the fused B(+) circuit to the relay output circuit. The powertrain control module is connected in parallel with the ASD relay output circuit. This connection provides the PCM with a circuit to monitor the ASD relay output state. Whenever the PCM energizes the ASD relay, it checks the feedback circuit to ensure voltage is present at the ASD relay output. If voltage is not present, a trouble code is set. Possible Causes: - ASD relay output circuit open - Fused B(+) circuit open - ASD relay - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 Amp fuse located in the PDC. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 1891 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 1892 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 1893 Automatic Shut Down (ASD) Relay: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions Absolute Pressure Sensor: Technical Service Bulletins Emissions/Engine Controls - Service Manual Revisions NUMBER: 26-06-97E GROUP: Miscellaneous DATE: June, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1996 2.0L, 2.4L, 2.5L, 3.3L, 3.8L Engine Diagnostic Manual - Publication Number 81-699-96104 DESCRIPTION OF CHANGES Engine controls - revisions Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 1900 501A Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 1901 501B Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 1902 501C Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 1903 501D Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 1904 502 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 1905 645 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 1906 645A Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 1907 645B Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Battery Temp Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1911 Battery Temp Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 1912 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > General Description Battery Temperature Sensor: Description and Operation General Description CIRCUIT OPERATION From circuit G31 the battery temperature sensor draws voltage from the Powertrain Control Module (PCM). The sensor is a variable resistor. As battery temperature changes, the resistance in the sensor changes causing a change in current draw. Circuit G31 connects to cavity 52 of the PCM connector. The PCM provides ground for the battery temperature sensor signal (circuit G31) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > General Description > Page 1915 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor Operation Sensor External to the PCM Name of Code: Battery Temp Sensor (BTS) Voltage Either Too High or Too Low When Monitored: With the ignition key on. Set Condition: The PCM senses the voltage from the BTS to be either below 0.5 volts or above 4.9 volts for 3 seconds. Theory of Operation: The battery temp sensor voltage is used by the PCM to determine what the charging system goal should be. The PCM uses that goal to determine the charging output level. The battery temp sensor is external to the PCM. Possible Causes: - Battery temp sensor failure - Open circuit in battery temp sensor signal circuit - Short circuit in battery temp sensor signal circuit - PCM failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Battery Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 1924 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1925 Camshaft Position Sensor: Locations Camshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1926 Camshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Operation Fig.9 Camshaft Position Sensor-DOHC PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity OPERATION Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 1929 The camshaft position sensor attaches to the rear of the cylinder head (Fig. 9). 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 (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. The sensor also acts as a thrust plate to control camshaft endplay. CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the camshaft position sensor The K7 circuit connects to cavity 44 of the PCM connector. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 33 of the PCM connector. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 1930 Camshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP Trouble Code Name of Code: Intermittent Loss of CMP or CKP When Monitored: During engine running. Set Condition: When the expected cam signal level disagrees with the actual cam signal level. Theory of Operation: After the engine has been started, the powertrain control module maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. Possible INTERMITTENT Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 1931 Camshaft Position Sensor: Description and Operation No Cam Signal at PCM Trouble Code Name of Code: No Cam Signal at PCM When Monitored: During engine cranking, after a number of crank position sensor signals have been detected. Set Condition: Signals are not received from the camshaft position sensor when signals are received from the crankshaft position sensor Theory of Operation: The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. The PCM supplies 8 volts and a sensor ground to the CMP sensor. The camshaft position sensor signal circuit has a 5 volt pull-up from the PCM. The sensor signal is created by a rotating target magnet attached to the rear of the camshaft when the north pole of the magnet passes under the sensor, the signal remains at 5 volts. When the south pole passes under the sensor, the signal drops to 0.3 volt. Possible Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and target magnet - Damaged target magnet - Failed sensor - Failed PCM - Broken timing belt - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 1934 Camshaft Position Sensor: Testing and Inspection Failure to Start Test This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 1935 Camshaft Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Sensor Replacement Fig. 8 Camshaft Position Sensor Location Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head (Fig. 8). REMOVAL 1. Remove filtered air tube from the throttle body and air cleaner housing. 2. Disconnect electrical connector from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.35 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft (Fig. 35). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 1938 Fig.36 Target Magnet Installation NOTE: The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft (Fig. 36). INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install filtered air tube. Tighten clamps to 3 Nm ±1 (25 in lb ±5) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 1939 Camshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 18 Nm (165 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1943 Engine Coolant Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1944 Engine Coolant Temperature Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1945 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig.13 Engine Coolant Temperature Sensor-DOHC PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the intake manifold next to the thermostat housing (Fig. 13). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine cool and temperature gauge in the instrument cluster on circuit G20. See: Engine, Cooling and Exhaust/Cooling System/Lamps and Indicators Cooling System/Temperature Gauge/Description and Operation From circuit K2 the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics Coolant Temperature Sensor/Switch (For Computer): Component Tests and General Diagnostics Helpful Information The engine coolant temperature sensor is case grounded. The case ground provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Component Testing Fig. 80 Engine Coolant Temperature Sensor Location-DOHC 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 80). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 1948 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.39 Engine Coolant Temperature Sensor-DOHC NOTE: The engine coolant temperature sensor threads into the rear of the cylinder head. New sensors have sealant applied to the threads. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. - Tighten to 18 Nm (165 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 1953 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position Sensor Bolts ........................................................................................................ .......................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1954 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1955 Crankshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor-PCM Input Fig. 15 Crankshaft Position Sensor Fig. 14 Timing Reference Notches Fig.6 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60° signature notch (Fig. 14). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 1958 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. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69° before top dead center (BTDC). - The second notch represents 49° BTDC. - The third notch represents 29°. - The last notch in each set represents 9° before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM connector. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 1959 Crankshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP Trouble Code Name of Code: Intermittent Loss of CMP or CKP When Monitored: During engine running. Set Condition: When the expected cam signal level disagrees with the actual cam signal level. Theory of Operation: After the engine has been started, the powertrain control module maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. Possible INTERMITTENT Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 1960 Crankshaft Position Sensor: Description and Operation No Crank Reference Signal at PCM Trouble Code Name of Code: No Crank Reference Signal at PCM When Monitored: During engine cranking, with battery voltage less than 11.5 volts and manifold vacuum present. Set Condition: No signal from the crankshaft position (CKP) sensor during engine cranking or there is a camshaft position sensor signal without a CKP sensor signal. Theory of Operation: The crankshaft position sensor is a hall-effect type sensor used to detect crankshaft speed and position. The PCM supplies 8 volts and a sensor ground to the CKP sensor. The crankshaft position sensor signal circuit has a 5-volt pull-up from the PCM. The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. When there isn't a notch under the sensor, the signal drops to 0.3 volt. Possible Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and crankshaft pulse ring - Damaged crankshaft pulse ring - Failed sensor - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 1963 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 1964 Crankshaft Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig. 12 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 12). 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Crankshaft Position Sensor Bolts torque ....................................................................................................................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 1967 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection Fuel Level Sensor: Testing and Inspection Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications MAP Sensor Torque Aluminum Manifold = 3 Nm (30 in lbs) Plastic Manifold = 2 Nm (20 in lbs) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 1974 Intake Air Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 1975 Intake Air Temperature Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Fig.15 MAP/IAT Sensor-DOHC PURPOSE The intake air temperature sensor measures the temperature of the air as it enters the engine. The sensor supplies one of the inputs the PCM uses to determine injector pulse-width. CONSTRUCTION The MAP/Intake Air Temperature (IAT) sensor, located on the intake manifold, combines the MAP and Intake Air Temperature (IAT) functions into one sensor. CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. Circuit K21 connects to cavity 37 of the PCM connector. From circuit K21 the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor As intake air temperature changes the resistance in the sensor changes causing a change in current draw. The PCM provides ground for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor > Page 1978 Intake Air Temperature Sensor: Description and Operation Intake Air Temp Sensor Voltage High Name of Code: Intake Air Temp Sensor Voltage High When Monitored: With the ignition on and the engine running. Set Condition: The intake air sensor circuit voltage at PCM cavity 37 goes above 4.9 volts. Theory of Operation: The intake air temperature sensor (IAT) is located in the intake manifold where it measures the temperature of the air that is about to enter the combustion chambers. The IAT is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. At high temperatures resistance decreases and the voltage will decrease. This allows the sensor to provide an analog voltage signal to PCM cavity 37. The PCM uses this signal to compensate for changes in air density due to temperature. Possible Causes: - Sensor signal circuit open - Sensor internally open - Sensor ground circuit open - Powertrain control module failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor > Page 1979 Intake Air Temperature Sensor: Description and Operation Intake Air Temp Sensor Voltage Low Name of Code: Intake Air Temp Sensor Voltage Low When Monitored: With the ignition on and the engine running. Set Condition: The intake air sensor circuit voltage at PCM cavity 37 goes below 0.157 volt. Theory of Operation: The intake air temperature sensor (IAT) is located in the intake manifold where it measures the temperature of the air that is about to enter the combustion chambers. The IAT is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. At high temperatures resistance decreases and the voltage will decrease. This allows the sensor to provide an analog voltage signal to PCM cavity 37. The PCM uses this signal to compensate for changes in air density due to temperature. Possible Causes: - Sensor signal circuit shorted to ground - Sensor internally shorted - Powertrain control module failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Intake Air Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Helpful Information > Page 1982 Intake Air Temperature Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 1983 Intake Air Temperature Sensor: Service and Repair Map/Intake Air Temperature Sensor Fig. 98 MAP/IAT Sensor-DOHC NOTE: The MAP/IAT sensor attaches to the intake manifold plenum (Fig. 98). Fig. 97 Air Inlet Duct-DOHC REMOVAL 1. Remove air inlet duct wing nut and duct from intake manifold (Fig. 97). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 1984 2. Disconnect the electrical connector from the MAP/IAT sensor. 3. Remove sensor mounting screws. 4. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seals. 2. Tighten mounting screws to 2 Nm (20 in lb) torque for a plastic manifold and 3 Nm (30 in lb) for a aluminum manifold. 3. Attach electrical connector to sensor 4. Install air inlet duct wing nut and duct from intake manifold, insure that the duct does not interfer with ignition cables. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 1988 Knock Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 1989 Knock Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation Knock Sensor: Description and Operation Knock Sensor Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 24 of the PCM connector. The PCM provides ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation > Page 1992 Knock Sensor: Description and Operation Knock Sensor Circuit Trouble Code Name of Code: Knock Sensor Circuit When Monitored: With the ignition on and the engine running. Set Condition: The knock sensor circuit voltage falls below a minimum value at idle or deceleration, The minimum value is from a look-up table internal to the PCM and is based on engine rpm. The trouble code also sets if the sensor output is above 5.0 volts. Theory of Operation: The knock sensor is mounted on the cylinder block below the intake manifold. The knock sensor is comprised of thin piezo-electric ceramic discs bonded to a metal diaphragm. When engine knock occurs, the diaphragm vibrates along with the piezoelectric discs, producing an electrical signal. The signal is used by the PCM to adjust ignition timing to eliminate the knock condition. Possible Causes: - Sensor signal open - Sensor internally open - PCM failure - Sensor signal circuit shorted to ground - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Helpful Information Knock Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 1995 Knock Sensor: Testing and Inspection Component Testing The knock sensor can be tested with a digital voltmeter. Sensor output should be between 80 mV and 4 volts with the engine running between 576 and 2,208 rpm. If the output falls outside of this range a DTC will be set. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 1996 Knock Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Page 1997 Knock Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications Manifold Pressure/Vacuum Sensor: Electrical Specifications The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications > Page 2002 Manifold Pressure/Vacuum Sensor: Mechanical Specifications MAP Sensor Torque Aluminum Manifold = 3 Nm (30 in lbs) Plastic Manifold = 2 Nm (20 in lbs) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2003 Map Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2004 IAT/Map Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure Sensor Fig.15 MAP/IAT Sensor-DOHC OPERATION The PCM supplies 5 volts to the MAP sen son The MAP sensor function converts intake manifold pressure into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage increases proportionately. During cranking, before the engine starts running, the PCM determines atmosphenc air pressure from the MAP sensor voltage. While the engine operates, the PCM determines intake manifold pressure from the MAP sensor voltage. Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and the air/fuel mixture. The MAP/Intake Air Temperature Sensor (MAP/IAT) sensor mounts to the intake manifold. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Manifold Absolute Pressure (MAP) sensor. Circuit K6 connects to cavity 61 of the PCM connector. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity 36 of the PCM connector. The PCM provides ground for the MAP sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor > Page 2007 Manifold Pressure/Vacuum Sensor: Description and Operation Related Trouble Codes & Set Conditions MAP Sensor Voltage Too High NAME OF CODE: MAP Sensor Voltage Too High WHEN MONITORED: With engine RPM above 400 but less than 1500 and the Throttle Position (TP) sensor voltage less than 1.0 volt. SET CONDITION: The manifold Absolute Pressure (MAP) sensor signal voltage is greater than 4.6 volts at start or with the engine running for 1.76 seconds. THEORY OF OPERATION: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to Powertrain Control Module (PCM) cavity 36. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at deep throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 61; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Open 5-volt supply circuit - Sensor open internally - Sensor ground circuit - Sensor signal circuit shorted to voltage - Failed PCM - Connector terminals - Connector wires MAP Sensor Voltage Too Low Name of Code: MAP Sensor Voltage Too Low When Monitored: With engine rpm above 400 but less than 1,500 and the TP sensor voltage less than 1.0 volt. Set Condition: The MAP sensor signal voltage is below 1.2 volts at start, or below 0.02 volt for 1.76 seconds with engine running. Theory of Operation: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to PCM cavity 36. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at deep throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 61; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 43. Possible Causes: - Open 5-volt supply circuit - Signal circuit shorted to ground - Failed sensor - PCM failure - Connector terminals - Connector wires No Change In MAP From Start to Run NAME OF CODE: No Change in MAP From Start to Run WHEN MONITORED: With engine RPM above 400 but less than 1500 and the throttle body at closed throttle. SET CONDITION: Too small a difference is seen between barometric pressure at ignition on and manifold vacuum (engine running) for 1.76 seconds. THEORY OF OPERATION: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor > Page 2008 Powertrain Control Module (PCM) cavity 36. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at deep throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 61; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Restricted or leaking vacuum/pressure to MAP sensor - Ice in sensor or passage - Failed sensor - Failed PCM TPS Voltage Does Not Agree With MAP Name of Code: TPS Voltage Does Not Agree with MAP When Monitored: With the engine running and no MAP sensor or TP sensor trouble codes. Set Condition: The powertrain control module (PCM) performs two separate tests on the TP sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 mph and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 4 continuous seconds. Theory of Operation: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from the PCM. The sensor ground is provided by the PCM. Possible Causes: - Failed powertrain control module - Connector wires - TP sensor failure - Vehicle speed - Mechanical failure - MAP sensor - Connector terminals Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing Manifold Pressure/Vacuum Sensor: Testing and Inspection Component Testing Fig. 82 MAP Sensor Connector CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 1 and 4 (Fig. 82). With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. If OK, go to next step. - If not OK, go to step 3. 2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness condition. Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 43. - If OK, go to next step. - If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 3 and 1 with the key ON. The voltage should be approximately 5 volts ± 0.5V). Five volts (± 0.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor. - If not OK, repair or replace the wire harness as required. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing > Page 2011 Manifold Pressure/Vacuum Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing > Page 2012 Manifold Pressure/Vacuum Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 2013 Manifold Pressure/Vacuum Sensor: Service and Repair Map/Intake Air Temperature Sensor Fig. 98 MAP/IAT Sensor-DOHC NOTE: The MAP/IAT sensor attaches to the intake manifold plenum (Fig. 98). Fig. 97 Air Inlet Duct-DOHC REMOVAL 1. Remove air inlet duct wing nut and duct from intake manifold (Fig. 97). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 2014 2. Disconnect the electrical connector from the MAP/IAT sensor. 3. Remove sensor mounting screws. 4. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seals. 2. Tighten mounting screws to 2 Nm (20 in lb) torque for a plastic manifold and 3 Nm (30 in lb) for a aluminum manifold. 3. Attach electrical connector to sensor 4. Install air inlet duct wing nut and duct from intake manifold, insure that the duct does not interfer with ignition cables. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Upstream and Downstream Heated Oxygen Sensors Torque = 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2020 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2021 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2022 Downstream Oxygen Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2023 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor Oxygen Sensor: Description and Operation Heated Oxygen Sensor CIRCUIT OPERATION Circuit A14 is a bus bar in the Power Distribution Center (PDC), and connects to battery voltage. The contact side of the Automatic Shut Down (ASD) relay connects circuit A14 and circuit A142. A 20 Amp fuse in the PDC protects circuits A14 and A142. Circuit A14 also supplies voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) controls the ground path circuit for the coil side of the ASD relay on circuit K51. Circuit K51 connects to cavity 67 of the PCM connector. Circuit A142 splices to supply voltage for the upstream and downstream heated oxygen sensors. The A142 circuit also splices to cavity 6 of the PCM. The input provided by circuit A142 at cavity 6 tells the PCM that the ASD relay energized. Circuit K41 delivers the signal from the upstream heated oxygen sensor to the PCM. Circuit K41 connects to cavity 30 of the PCM connector. Circuit K141 delivers the signal from the down-stream heated oxygen sensor to the PCM. Circuit K141 connects to cavity 51 of the PCM connector. The PCM provides a ground for the upstream and downstream heated oxygen sensor signals (circuit K41 and K141) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector Circuit Z1 provides ground for the heater circuits in each sensor. Circuit Z1 terminates at the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor > Page 2026 Oxygen Sensor: Description and Operation Related Trouble Codes & Set Conditions Downstream O2 Sensor Heater Failure Name of Code: Downstream O2 Sensor Heater Failure When Monitored: With the ignition key oft, after the engine cools down Set Condition: No sensor output signal is received when the PCM powers up the sensor heater. Theory of Operation: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this 02 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases the downstream oxygen sensor tells the PCM how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. This O2 sensor serves as an indicator of oxygen content. The heater element helps the O2 sensor quickly reach a normal and steady operating temperature, which is required for proper emission control. Possible Causes: - Open heater element circuit - O2 sensor failure - Powertrain control module failure - Connector terminals - Connector wires Downstream O2 Sensor Shorted to Ground Name of Code: Downstream O2S Voltage Shorted To Ground When Monitored: With the ignition key off, after the engine cools down. Set Condition: The downstream oxygen sensor signal voltage is below 0.156 volt prior to O2 sensor heater test. Theory of Operation: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the PCM how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. Variations in the signal from the O2 sensor serve as an indicator of oxygen content. The catalytic converter absorbs the oxygen in the exhaust gas when the fuel/air mixture is lean. The downstream 02 sensor indicates a deficiency of oxygen when the upstream 02 sensor detects an abundance of oxygen and vice versa. Possible Causes: - Sensor output wire shorted to another circuit - Dirty connection causing voltage tracking in connector - O2 sensor failure - Powertrain control module failure - Connector terminals/wires Downstream O2 Sensor Shorted to Voltage Name of Code: Downstream O2 Sensor Shorted To Voltage When Monitored: With the ignition key on. Set Condition: The engine running for more than 2 minutes and coolant temp. above 176°F. The upstream oxygen sensor signal voltage is above 1.2 volts for 2.6 seconds. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor > Page 2027 Theory of Operation: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. Possible Causes: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure - Powertrain control module failure - Connector terminals - Connector wires Downstream O2 Sensor Stays at Center Name of Code: Downstream O2 Sensor Stays At Center When Monitored: With the vehicle engine running for more than two minutes, engine temperature greater than 170°F, in closed loop. Set Condition: If oxygen sensor voltage stays between 0.29 volts and 0.72 volts for 30 seconds, the PCM pulls the sensor voltage to 5.0 volts for 60 seconds and monitors the sensor voltage. If the voltage stays at 5.0 volts, this trouble code will set, indicating no activities. Theory of Operation: Effective control of exhaust emissions is achieved by an oxygen feedback system. The downstream oxygen sensor (O2S), located in the exhaust path, monitors the exhaust emissions. Once the sensor reaches its normal operating temperature of 300°-350° C (572°-662° F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the efficiency of the catalytic converter. The downstream oxygen sensor is monitored for proper response to assure a correct catalytic converter efficiency calculation. A good sensor will indicate a rich condition when at WOT (due to the enriched F/A ratio), and a lean condition when in decel fuel shut-off (due to the lean F/A ratio). Possible Causes: - Sensor output wire open - Dirt/moisture/grease inside connector - Open ground circuit - Oxygen sensor failure - PCM failure Slow Upstream O2 Sensor During Catalyst Monitor Name of Code: Slow Upstream O2 Sensor During Catalyst Monitor When Monitored: With the engine running, coolant greater than 17O°F, open throttle, steady to slightly increasing vehicle speed between 18 MPH and 55 MPH, with a light load on the engine, for a period no less than five minutes. Set Condition: The upstream oxygen sensor signal voltage is switching from below 0.39 volt to above 0.6 volt and back fewer times than required. Theory of Operation: Effective control of exhaust emissions is achieved by an oxygen feedback system, of which the most important element is the upstream oxygen sensor (O2S). which is located in the exhaust path. Once the sensor reaches its normal operating temperature of 30O° to 350°C (572° to 662°F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the fuel injector pulse width, which maintains the optimum 14.7 to 1 air/fuel (A/F) ratio that is required for the catalytic converter to best control exhaust emissions. Response rate is the time required for the sensor to detect changes in the exhaust gas oxygen content; it switches from lean to rich if it is exposed to a richer than optimum A/F mixture, or vice versa. The O2S output voltage ranges from 0 to 1 volt. A good sensor easily generates an output voltage in this range as it is exposed to different oxygen concentrations. To detect a shift in the A/F mixture (lean or rich), the output voltage has to change beyond a threshold value. A malfunctioning sensor could have difficulty changing beyond the thresholds. Possible Causes: - Exhaust leak Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor > Page 2028 - Dirt/moisture/grease inside connector - Fuel contamination - Engine mechanical - Weak upstream O2 sensor with deteriorated catalyst Upstream O2 Sensor Heater Failure Name of Code: Upstream O2 Sensor Heater Failure When Monitored: With the Ignition key off, after the engine cools down. Set Condition: No sensor output signal is received when the PCM powers up the sensor heater. Theory of Operation: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases. the upstream oxygen sensor tells the PCM how well its output signal is controlling the air/fuel ratio. Variations in the signals from the O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/ fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. The heater element helps the 02 sensor quickly reach a normal and steady operating temperature. which is required for proper emission control. Possible Causes: - Open heater element circuit - 02 sensor failure - PCM failure - Dirt/moisture/grease inside connector - 02 sensor heater wires - ASD relay failure Upstream O2 Sensor Shorted to Voltage Name of Code: Upstream 02 Sensor Shorted to Voltage When Monitored: With the ignition key on. Set Condition: The engine running for more than 2 minutes and coolant temperature above 176°F. The upstream oxygen sensor signal voltage is above 1.2 volts for 2.6 seconds. Theory of Operation: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. Possible Causes: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - 02 sensor failure - Powertrain control module failure - Connector terminals - Connector wires Upstream O2 Sensor Slow Response Name of Code: Upstream O2 Sensor Slow Response When Monitored: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor > Page 2029 With the engine running for more than 3 minutes, engine temperature greater than 120°F, after reaching a vehicle speed of 20 mph for 120 seconds, at idle with the transmission in drive (auto) or in neutral (manual). Set Condition: The upstream oxygen sensor signal voltage is switching from below 0.39 volt to above 0.6 volt and back fewer times than required. Theory of Operation: Effective control of exhaust emissions is achieved by an oxygen feedback system, of which the most important element is the upstream oxygen sensor (O2S), which is located in the exhaust path. Once the sensor reaches its normal operating temperature of 300°C-350°C (572°F - 662°F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the fuel injector pulse width, which maintains the optimum 14.7 to 1 air/fuel (A/F) ratio that is required for the catalytic converter to best control exhaust emissions. Response rate is the time required for the sensor to detect changes in the exhaust gas oxygen content; it switches from lean to rich if it is exposed to a richer than optimum A/F mixture, or vice versa. The O2S output voltage ranges from 0 to 1 volt. A good sensor easily generates an output voltage in this range as it is exposed to different oxygen concentrations. To detect a shift in the A/F mixture (lean or rich), the output voltage has to change beyond a threshold value. A malfunctioning sensor could have difficulty changing beyond the thresholds. Possible Causes: - Exhaust leak - Dirt/moisture/grease inside connector - Fuel contamination - Engine mechanical Upstream O2 Sensor Stays at Center Name of Code: Upstream O2 Sensor Stays at Center When Monitored: With the engine running for more than 2 minutes and engine temperature greater than 17O°F. Set Condition: The upstream oxygen sensor signal voltage is between 0.35 volts and 0.55 volts for 1.5 minutes. Theory of Operation: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this 02 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. Possible Causes: - Sensor output wire open - O2 sensor failure - PCM failure - Dirt/moisture/grease causing voltage tracking in connector - Connector wires Upstream O2S Voltage Shorted to Ground Name of Code: Upstream 02S Voltage Shorted To Ground When Monitored: With engine coolant temperature above 170°F on the previous key on, after a cold start, engine coolant below 98°F, and ambient/ battery sensor reading within 27°F of engine coolant. Set Condition: The upstream oxygen sensor signal voltage is below 0.156 volts for 28 seconds after starting engine. Theory of Operation: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from the O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be low, approximately 0.1 volt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor > Page 2030 Possible Causes: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure - Powertrain control module failure - Connector terminals - Connector wires to sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, ASD relay, generator, and the upstream and downstream heated oxygen sensors. The PCM controls the ground circuit for each of the components powered by circuit A142. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2033 Oxygen Sensor: Testing and Inspection Oxygen Sensor Heater Circuit Test NOTE: Use an ohmmeter to test the heating element of the oxygen sensors. 1. Disconnect the electrical connector from each oxygen sensor. - The white wires in the sensor connector are the power and ground circuits for the heater elements. 2. Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. - Replace the heated oxygen sensor if the resistance is not between 4 and 7 ohms. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor Oxygen Sensor: Service and Repair Downstream O2 Sensor Fig. 19 Downstream Heated Oxygen Sensor NOTE: The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic convertor (Fig. 19). REMOVAL 1. Raise vehicle. 2. Disconnect electrical connector from sensor. 3. Disconnect sensor electrical harness from clips along body. Fig. 20 Downstream Heated Oxygen Sensor Removal/Installation 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 20). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 2036 Oxygen Sensor: Service and Repair Upstream O2 Sensor Fig. 18 Upstream Heated Oxygen Sensor Removal/Installation REMOVAL 1. Raise and support vehicle. 2. Unplug sensor connector. 3. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 18). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 2037 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 2042 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2043 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2044 Power Steering Pressure Switch: Description and Operation Fig. 15 Power Steering Pressure Switch PURPOSE On vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. The pressure switch improves vehicle idle quality, by controlling engine idle speed when required. The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed is increased. This increase in engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The power steering pressure switch is mounted directly to the power steering gear on vehicles requiring its usage. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z12 provides ground for the power steering pressure switch. The grounding point for circuit Z12 is the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2045 Power Steering Pressure Switch: Testing and Inspection Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: Customer Interest Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 2054 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: All Technical Service Bulletins Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 2060 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Fresh Air Duct - Contacts Hood Insulator Pad NO: 14-05-96 GROUP: Fuel DATE: June 7, 1996 SUBJECT: Wear Marks On Fresh Air Duct And Hood Pad MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES BUILT WITH SPORT/EXPRESSO BUBBLE HOODS AND 2.0L SOHC ENGINES. SYMPTOM/CONDITION: Wear marks on either the fresh air duct or hood pad, due to contact between the two components may be visible. The contact between the fresh air duct and hood pad do not result in a functional problem, but the indentations may be objectional to the customer. PARTS REQUIRED: 1 4669962 Duct, Fresh Air REPAIR PROCEDURE: This bulletin involves the installation of a new fresh air duct which provides additional clearance. 1. Remove the plastic wing nut from the fresh air duct mount. See Illustration. 2. Remove the fresh air duct from the air cleaner box. 3. Install new fresh air duct (P/N 4669962) in the air cleaner box. CAUTION: THE FRESH AIR DUCT MUST BE COMPLETELY SNAPPED INTO THE AIR CLEANER BOX. VERIFY THAT THE DUCT IS FIRMLY IN PLACE. 4. Install the wing nut, while pushing down in the marked area of the fresh air duct. See Illustration. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad > Page 2066 TIME ALLOWANCE: Labor Operation No: 14-10-29-92 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad > Page 2072 TIME ALLOWANCE: Labor Operation No: 14-10-29-92 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2075 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2076 Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2077 Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS mounts to the throttle body and connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- from 0.38 to 1.03 volts. - AT Wide open throttle -- 3.1 to 4.0 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). CIRCUIT OPERATION From the Powertrain Control Module (PCM) circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 2080 Throttle Position Sensor: Description and Operation Related Trouble Codes & Set Conditions Throttle Position Sensor Voltage High Name of Code: Throttle Position Sensor Voltage High When Monitored: With the ignition on. Set Condition: TP sensor voltage at PCM cavity 35 goes above 4.5 volts for 0.704 seconds. Theory of Operation: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 35. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. Possible Causes: - Sensor signal circuit open - Throttle position sensor failure - Sensor ground circuit open - PCM failure - Connector terminals - Connector wires Throttle Position Sensor Voltage Low NAME OF CODE: Throttle Position Sensor Voltage Low WHEN MONITORED: With the ignition ON. SET CONDITION: The Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 35 goes below 0.2 volt for 0.704 seconds, or MPH is above 20, RPM is above 1500, and vacuum is below 2" with TP sensor voltage less than 0.5 volt for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Throttle position sensor failure - Loss of 5-volt supply TPS Voltage Does Not Agree With MAP Name of Code: TPS Voltage Does Not Agree with MAP When Monitored: With the engine running and no MAP sensor or TP sensor trouble codes. Set Condition: The powertrain control module (PCM) performs two separate tests on the TP sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 mph and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 4 continuous seconds. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 2081 Theory of Operation: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from the PCM. The sensor ground is provided by the PCM. Possible Causes: - Failed powertrain control module - Connector wires - TP sensor failure - Vehicle speed - Mechanical failure - MAP sensor - Connector terminals Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2084 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor around terminal. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately 0.38 volts to 1.03 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.0 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2085 Throttle Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2086 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2087 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (20 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Throttle Position Sensor Mounting Screws 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2091 Transmission Connections Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 2094 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 2095 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 2096 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 2097 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 2098 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 2099 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 2100 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 2101 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 2102 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 2103 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 2104 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 2105 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 2106 Transmission Position Switch/Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 2107 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 2108 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 2109 Rear Lighting (Part 1 Of 3) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Park/Neutral Position Switch Operation Transmission Position Switch/Sensor: Description and Operation Park/Neutral Position Switch Operation Fig. 20 Park/Neutral Switch OPERATION The park/neutral position switch is located on the automatic transaxle housing Fig. 20. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. CIRCUIT OPERATION When CLOSED the Transmission Range Switch (TRS) provides an input to the Powertrain Control Module (PCM) on circuit T41. This circuit connects to cavity 76 of the PCM connector. The T41 circuit is spliced and provides a ground path for the engine starter relay, and the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Park/Neutral Position Switch Operation > Page 2112 Transmission Position Switch/Sensor: Description and Operation Park/Neutral Switch Failure Trouble Code Name of Code: Park/Neutral Switch Failure (Sense Circuit) When Monitored: With the transmission in Park, Neutral, or Drive and not in limp-in mode. Set Condition: This code is set if the PCM detects an incorrect Park/Neutral switch state for a given mode of vehicle operation. Theory of Operation: The Transmission range Sensor (Park/Neutral position switch on 3 speed auto and all manual trans) is used to communicate whether or not the transmission is in Park or Neutral to the PCM. When the transmission is in Park or Neutral the Park/Neutral position switch sense circuit is grounded. Possible Causes: - Connector terminals and/or wires - Park/Neutral switch failure - Mechanical transmission problem - PCM failure Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Page 2113 Transmission Position Switch/Sensor: Testing and Inspection Park/Neutral Starting and Back-Up Lamp Switch 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 the switch, remove the wiring connector from the switch and test for continuity between the center pin of the switch and the transaxle case. Continuity should exist only when the transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 1. To test the switch, remove the wiring connector from the switch and test for continuity between the two outside pins. Continuity should only exist with the transaxle in the REVERSE position. 2. No continuity should exist from either pin to the transaxle case. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Page 2114 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Starting and Back-Up Lamp Switch Removal 1. Place a suitable container under the switch to catch fluid when switch is removed. 2. Unscrew switch from transaxle case allowing fluid to drain into container. 3. Move selector lever to PARK, then NEUTRAL position and inspect to see the switch operating lever fingers are centered in the switch opening. Installation 1. Crew the switch with a new seal into the transaxle case and tighten to 33 Nm (24 ft. lbs.). 2. Test switch with a test lamp. 3. Add fluid to transaxle to bring up to proper level. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Mounting Bolt 2.2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2118 Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2121 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2122 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2123 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2124 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2125 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2126 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2127 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2128 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2129 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2130 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2131 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2132 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2133 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2134 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2135 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2136 Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > No Vehicle Speed Sensor Signal Trouble Code Vehicle Speed Sensor: Description and Operation No Vehicle Speed Sensor Signal Trouble Code With Electronic Automatic Transaxle NAME OF CODE: No Vehicle Speed Sensor Signal WHEN MONITORED: With engine running more than 31 seconds, engine temperature greater than 120°F, transmission not in park or neutral, brakes not applied, engine RPM greater than 1800, and MAP vacuum less than 11". SET CONDITION: No signal from the vehicle speed sensor (VSS) for more than 11 seconds. THEORY OF OPERATION: The vehicle speed sensor signal is provided to the PCM by the TCM. The signal is calculated by the TCM based on the output speed sensor signal and the speedometer pinion factor. The PCM supplies a 5 volt pull up voltage from cavity 66 to TCM cavity 58. The sensor signal is created by the TCM alternating the signal from 5V to 0.3V. POSSIBLE CAUSES: - Open or shorted signal circuit - Speedometer pinion factor not programmed - Open vehicle speed sensor circuit - PCM failure - TCM failure Without Electronic Automatic Transaxle Name of Code: No Vehicle Speed Sensor Signal When Monitored: With engine running more than 31 seconds, engine temperature greater than 180°F, transmission not in park or neutral, brakes not applied, engine rpm greater than 1,800, and MAP vacuum less than 11". Set Condition: No signal from the vehicle speed sensor for more than 11 seconds. Theory of Operation: The vehicle speed sensor is a hall-effect type sensor used to detect the transmission output shaft speed. The PCM calculates the vehicle speed based on the VSS signal. The PCM supplies 8 volts to power up the sensor. Sensor ground is supplied by the PCM. The PCM also supplies a 5.0 volt pull up voltage to the sensor. The VSS signal is created when the sensor alternates the 5.0 volt pull up from high to low. Possible Causes: - Open or shorted signal circuit - Speedometer pinion damaged - Open 5-volt supply circuit - Open sensor ground circuit - Failed vehicle speed sensor - PCM failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > No Vehicle Speed Sensor Signal Trouble Code > Page 2139 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor-PCM Input Fig. 17 Vehicle Speed Sensor -- Automatic Transmission Fig. 18 Vehicle Speed Sensor -- Manual Transmission PURPOSE The sensor input is used by the PCM to determine vehicle speed and distance traveled. OPERATION The vehicle speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. Under deceleration conditions, the PCM adjusts the Idle Air Control (IAC) motor to maintain a desired MAP value. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. The vehicle speed sensor signal is also used to operate: Speedometer - Speed control - Daytime Running Lights (Canadian Vehicles only). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the Vehicle Speed Sensor (VSS). The K7 circuit connects to cavity 44 of the PCM connector. Circuit G7 from the VSS provides an input signal to the PCM. The G7 circuit connects to cavity 66 of the PCM connector. The PCM provides ground for the VSS signal (circuit G7) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Helpful Information Vehicle Speed Sensor: Testing and Inspection Helpful Information Circuit G7 splices to the speedometer and odometer in the instrument cluster. Circuit K7 splices to supply 8 Volts to the camshaft position sensor and crankshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2142 Vehicle Speed Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 2143 Vehicle Speed Sensor: Service and Repair Fig. 24 Vehicle Speed Sensor Fig. 7 Vehicle Speed Sensor And Connector Fig. 8 Vehicle Speed Sensor And Speedometer Pinion Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 2144 NOTE: The vehicle speed sensor is located in the transmission extension housing (Fig. 24). REMOVAL 1. Disconnect electrical connector from sensor. 2. Remove the sensor mounting bolt. 3. Lift the sensor out of the transaxle extension housing. Ensure the 0-ring was removed with the sensor. NOTE: The speed sensor gear meshes with a gear on the output shaft. INSTALLATION 1. With 0-ring in place, install sensor and seat sensor by hand -- to ensure proper gear engagement. 2. Install mounting bolt and torque bolt to 2.2 Nm (20 in lb). 3. Connect electrical connector to sensor. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: Customer Interest Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 2154 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: All Technical Service Bulletins Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 2160 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2163 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2164 Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2165 Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS mounts to the throttle body and connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- from 0.38 to 1.03 volts. - AT Wide open throttle -- 3.1 to 4.0 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). CIRCUIT OPERATION From the Powertrain Control Module (PCM) circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 2168 Throttle Position Sensor: Description and Operation Related Trouble Codes & Set Conditions Throttle Position Sensor Voltage High Name of Code: Throttle Position Sensor Voltage High When Monitored: With the ignition on. Set Condition: TP sensor voltage at PCM cavity 35 goes above 4.5 volts for 0.704 seconds. Theory of Operation: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 35. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. Possible Causes: - Sensor signal circuit open - Throttle position sensor failure - Sensor ground circuit open - PCM failure - Connector terminals - Connector wires Throttle Position Sensor Voltage Low NAME OF CODE: Throttle Position Sensor Voltage Low WHEN MONITORED: With the ignition ON. SET CONDITION: The Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 35 goes below 0.2 volt for 0.704 seconds, or MPH is above 20, RPM is above 1500, and vacuum is below 2" with TP sensor voltage less than 0.5 volt for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Throttle position sensor failure - Loss of 5-volt supply TPS Voltage Does Not Agree With MAP Name of Code: TPS Voltage Does Not Agree with MAP When Monitored: With the engine running and no MAP sensor or TP sensor trouble codes. Set Condition: The powertrain control module (PCM) performs two separate tests on the TP sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 mph and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 4 continuous seconds. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 2169 Theory of Operation: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from the PCM. The sensor ground is provided by the PCM. Possible Causes: - Failed powertrain control module - Connector wires - TP sensor failure - Vehicle speed - Mechanical failure - MAP sensor - Connector terminals Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2172 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor around terminal. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately 0.38 volts to 1.03 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.0 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2173 Throttle Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2174 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2175 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (20 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2183 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2184 Camshaft Position Sensor: Locations Camshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2185 Camshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Operation Fig.9 Camshaft Position Sensor-DOHC PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity OPERATION Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 2188 The camshaft position sensor attaches to the rear of the cylinder head (Fig. 9). 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 (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. The sensor also acts as a thrust plate to control camshaft endplay. CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the camshaft position sensor The K7 circuit connects to cavity 44 of the PCM connector. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 33 of the PCM connector. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 2189 Camshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP Trouble Code Name of Code: Intermittent Loss of CMP or CKP When Monitored: During engine running. Set Condition: When the expected cam signal level disagrees with the actual cam signal level. Theory of Operation: After the engine has been started, the powertrain control module maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. Possible INTERMITTENT Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 2190 Camshaft Position Sensor: Description and Operation No Cam Signal at PCM Trouble Code Name of Code: No Cam Signal at PCM When Monitored: During engine cranking, after a number of crank position sensor signals have been detected. Set Condition: Signals are not received from the camshaft position sensor when signals are received from the crankshaft position sensor Theory of Operation: The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. The PCM supplies 8 volts and a sensor ground to the CMP sensor. The camshaft position sensor signal circuit has a 5 volt pull-up from the PCM. The sensor signal is created by a rotating target magnet attached to the rear of the camshaft when the north pole of the magnet passes under the sensor, the signal remains at 5 volts. When the south pole passes under the sensor, the signal drops to 0.3 volt. Possible Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and target magnet - Damaged target magnet - Failed sensor - Failed PCM - Broken timing belt - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2193 Camshaft Position Sensor: Testing and Inspection Failure to Start Test This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2194 Camshaft Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Sensor Replacement Fig. 8 Camshaft Position Sensor Location Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head (Fig. 8). REMOVAL 1. Remove filtered air tube from the throttle body and air cleaner housing. 2. Disconnect electrical connector from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.35 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft (Fig. 35). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 2197 Fig.36 Target Magnet Installation NOTE: The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft (Fig. 36). INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install filtered air tube. Tighten clamps to 3 Nm ±1 (25 in lb ±5) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 2198 Camshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2203 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position Sensor Bolts ........................................................................................................ .......................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2204 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2205 Crankshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor-PCM Input Fig. 15 Crankshaft Position Sensor Fig. 14 Timing Reference Notches Fig.6 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60° signature notch (Fig. 14). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 2208 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. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69° before top dead center (BTDC). - The second notch represents 49° BTDC. - The third notch represents 29°. - The last notch in each set represents 9° before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM connector. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 2209 Crankshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP Trouble Code Name of Code: Intermittent Loss of CMP or CKP When Monitored: During engine running. Set Condition: When the expected cam signal level disagrees with the actual cam signal level. Theory of Operation: After the engine has been started, the powertrain control module maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. Possible INTERMITTENT Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 2210 Crankshaft Position Sensor: Description and Operation No Crank Reference Signal at PCM Trouble Code Name of Code: No Crank Reference Signal at PCM When Monitored: During engine cranking, with battery voltage less than 11.5 volts and manifold vacuum present. Set Condition: No signal from the crankshaft position (CKP) sensor during engine cranking or there is a camshaft position sensor signal without a CKP sensor signal. Theory of Operation: The crankshaft position sensor is a hall-effect type sensor used to detect crankshaft speed and position. The PCM supplies 8 volts and a sensor ground to the CKP sensor. The crankshaft position sensor signal circuit has a 5-volt pull-up from the PCM. The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. When there isn't a notch under the sensor, the signal drops to 0.3 volt. Possible Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and crankshaft pulse ring - Damaged crankshaft pulse ring - Failed sensor - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 2213 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 2214 Crankshaft Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig. 12 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 12). 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Crankshaft Position Sensor Bolts torque ....................................................................................................................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2217 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation Fig.16 Ignition Lock Cylinder Detents The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detents: Accessory - Off (lock) - Unlock - On/Run - Start Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 2222 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Detentes The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detentes: Accessory - Off (lock) - Unlock - On/Run - Start REMOVAL 1. Disconnect negative cable from battery. 2. Place key cylinder in RUN position. - Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. - Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. - To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. - Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Connect negative cable to battery Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 2226 Knock Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 2227 Knock Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation Knock Sensor: Description and Operation Knock Sensor Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 24 of the PCM connector. The PCM provides ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation > Page 2230 Knock Sensor: Description and Operation Knock Sensor Circuit Trouble Code Name of Code: Knock Sensor Circuit When Monitored: With the ignition on and the engine running. Set Condition: The knock sensor circuit voltage falls below a minimum value at idle or deceleration, The minimum value is from a look-up table internal to the PCM and is based on engine rpm. The trouble code also sets if the sensor output is above 5.0 volts. Theory of Operation: The knock sensor is mounted on the cylinder block below the intake manifold. The knock sensor is comprised of thin piezo-electric ceramic discs bonded to a metal diaphragm. When engine knock occurs, the diaphragm vibrates along with the piezoelectric discs, producing an electrical signal. The signal is used by the PCM to adjust ignition timing to eliminate the knock condition. Possible Causes: - Sensor signal open - Sensor internally open - PCM failure - Sensor signal circuit shorted to ground - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Helpful Information Knock Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2233 Knock Sensor: Testing and Inspection Component Testing The knock sensor can be tested with a digital voltmeter. Sensor output should be between 80 mV and 4 volts with the engine running between 576 and 2,208 rpm. If the output falls outside of this range a DTC will be set. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2234 Knock Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Page 2235 Knock Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Typical -- SOHC Shown Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Curb idle speed ................................................................................................................................... .......................................................... 700 +/- 100 rpm Idle speed when A/C is ON (in neutral) .......... .......................................................................................................................................................... 850 rpm Basic idle speed .................................................................................................................... .......................................................................... 700 +/- 50 rpm NOTE: If these specs differ from the under hood label, then use the information found on the under hood label. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2244 Idle Speed: Testing and Inspection Fig. 31 PCV Vacuum Nipple 1. Turn ignition key off. 2. Disconnect the PCV valve hose from the intake manifold nipple (Fig. 31). Cap the PCV vacuum nipple. Fig. 32 Purge Hose 3. Disconnect purge hose from the nipple on the throttle body (Fig. 32). Fig. 33 Orifice 6457 Attached To Purge Nipple 4. Use a piece of hose to attach Air Metering Orifice 6457 (0.125 in. orifice) or equivalent, to the purge nipple on the throttle body (Fig. 33). 5. Ensure that all accessories are off. 6. Connect the DRB or equivalent scan tool to the data link connector inside the passenger compartment. 7. Run engine in Park or Neutral until the cooling fan has cycled on and off at least once (180°F). 8. Using the DRB or equivalent scan tool, access Minimum Airflow Idle Speed. 9. The following will then occur: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2245 - Idle air control motor will fully close - Idle spark advance will become fixed - PCM will go open loop enriched - DRB or equivalent scan tool displays engine RPM 10. If idle RPM is within the range shown below, throttle body minimum airflow is set correctly. Odometer Reading Idle RPM Below 1,000 Miles 550 - 1,300 RPM Above 1,000 Miles 600 - 1,300 RPM 11. If idle RPM is above specifications, use the DRB or equivalent scan tool to check idle air control motor operation. If idle air control motor is OK, replace throttle body. If idle air flow is below specification, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash thoroughly after using cleaner. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when is closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 14. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 12. Shut off engine. 13. Remove Air Metering Orifice 6457 or equivalent. Install purge hose. 14. Remove cap from PCV valve. Connect hose to PCV valve. 15. Remove DRB or equivalent scan tool. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad Air Cleaner Fresh Air Duct/Hose: Customer Interest Fresh Air Duct - Contacts Hood Insulator Pad NO: 14-05-96 GROUP: Fuel DATE: June 7, 1996 SUBJECT: Wear Marks On Fresh Air Duct And Hood Pad MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES BUILT WITH SPORT/EXPRESSO BUBBLE HOODS AND 2.0L SOHC ENGINES. SYMPTOM/CONDITION: Wear marks on either the fresh air duct or hood pad, due to contact between the two components may be visible. The contact between the fresh air duct and hood pad do not result in a functional problem, but the indentations may be objectional to the customer. PARTS REQUIRED: 1 4669962 Duct, Fresh Air REPAIR PROCEDURE: This bulletin involves the installation of a new fresh air duct which provides additional clearance. 1. Remove the plastic wing nut from the fresh air duct mount. See Illustration. 2. Remove the fresh air duct from the air cleaner box. 3. Install new fresh air duct (P/N 4669962) in the air cleaner box. CAUTION: THE FRESH AIR DUCT MUST BE COMPLETELY SNAPPED INTO THE AIR CLEANER BOX. VERIFY THAT THE DUCT IS FIRMLY IN PLACE. 4. Install the wing nut, while pushing down in the marked area of the fresh air duct. See Illustration. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad > Page 2255 TIME ALLOWANCE: Labor Operation No: 14-10-29-92 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Fresh Air Duct - Contacts Hood Insulator Pad NO: 14-05-96 GROUP: Fuel DATE: June 7, 1996 SUBJECT: Wear Marks On Fresh Air Duct And Hood Pad MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES BUILT WITH SPORT/EXPRESSO BUBBLE HOODS AND 2.0L SOHC ENGINES. SYMPTOM/CONDITION: Wear marks on either the fresh air duct or hood pad, due to contact between the two components may be visible. The contact between the fresh air duct and hood pad do not result in a functional problem, but the indentations may be objectional to the customer. PARTS REQUIRED: 1 4669962 Duct, Fresh Air REPAIR PROCEDURE: This bulletin involves the installation of a new fresh air duct which provides additional clearance. 1. Remove the plastic wing nut from the fresh air duct mount. See Illustration. 2. Remove the fresh air duct from the air cleaner box. 3. Install new fresh air duct (P/N 4669962) in the air cleaner box. CAUTION: THE FRESH AIR DUCT MUST BE COMPLETELY SNAPPED INTO THE AIR CLEANER BOX. VERIFY THAT THE DUCT IS FIRMLY IN PLACE. 4. Install the wing nut, while pushing down in the marked area of the fresh air duct. See Illustration. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad > Page 2261 TIME ALLOWANCE: Labor Operation No: 14-10-29-92 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Fig. 104 Air Intake Duct Fig. 105 Removal/Installation of Air Inlet Duct NOTE: Neon vehicles do not use a heated air inlet system. The PCM adjusts fuel injector pulse width and ignition timing to compensate for different ambient temperatures. NOTE: The air cleaner attaches to a bracket on the rear of the cylinder head. An ambient air duct supplies underhood air for the engine. REMOVAL 1. Remove air intake tube (Fig. 104) from air cleaner and intake manifold (Fig. 105). Fig. 106 Removal/Installation Air Cleaner Front Housing and Element 2. Tighten clasps on top of air cleaner housing. Rotate front of housing forward then lift front away from air cleaner housing (Fig 106). 3. Remove air cleaner element from front housing (Fig. 106). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2265 INSTALLATION 1. Install air cleaner element into front housing. 2. Rotate front of housing forward then lower into place and locate tabs in slots. - Fasten clasps on top of air cleaner housing. - Install air intake duct at air cleaner and intake manifold. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2270 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 12 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) 6. Replace Pressure test port cap when finished releasing pressure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications 1995 - 1996 2.0L, 2.4L Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Cable Routing and Firing Order Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum Cables #1 & #4 3,050 Ohms 4,250 Ohms Cables #2 & #3 2,300 Ohms 3,300 Ohms Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2281 Ignition Cable: Description and Operation NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Plastic clips in various locations protect the cables from damage. When the cables are replaced the clips must be used to prevent damage to the cables. The #1 cable must be routed under the PCV hose and clipped to the #2 cable. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Ignition Cable: Initial Inspection and Diagnostic Overview Fig. 3 Spark Plug Cables NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Be sure that the plastic clip on PCV hose is positioned so that cable clip is beneath hose, and that #1 cable is snapped into this clip to protect it from metal PCV clamp. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2284 Ignition Cable: Component Tests and General Diagnostics Testing For Open Circuits, High Resistance and Loose Terminals Use an ohmmeter to check cables for opens, loose terminals or high resistance as follows: 1. Remove cable from spark plug. 2. Remove cable from the coil tower. 3. Connect the ohmmeter between the spark plug end terminal and the coil end terminal. - Make sure ohmmeter probes are in good contact. - Resistance should be within tolerance shown in the cable resistance chart. - If resistance is not within tolerance, replace cable assembly. Test all spark plug cables in the same manner. - If no problems are found, SEE Ignition System/System Diagnosis/Testing For Spark At Coil. SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum Cables #1 & #4 3,050 Ohms 4,250 Ohms Cables #2 & #3 2,300 Ohms 3,300 Ohms Testing For Punctures and Cracks When testing cables for punctures and cracks with an oscilloscope and an inductive voltage probe, follow the instructions of the equipment manufacturers. CAUTION: Do not leave any one spark plug cable disconnected for more than 30 seconds during test or possible heat damage to catalytic converter will occur. If an oscilloscope and inductive probe are not available, cables can be tested as follows: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. WARNING: The ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. 2. With the engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). - If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. - Replace cracked, leaking or faulty cables. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning Ignition Cable: Service and Repair Cleaning Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Cleaning > Page 2287 Ignition Cable: Service and Repair Replacement Fig. 3 Spark Plug Cables NOTE: The cables insulate the spark plugs and cover the top of the spark plug tube (Fig. 3). CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. REMOVAL 1. Remove spark plug cable from coil first. Lightly grasp the top of the cable. 2. Rotate the insulator 1/2 turn and pull straight up in a steady motion. 3. To replace the cables, disconnect the cable from the ignition coil. INSTALLATION Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube.Then connect the other end to coil pack. Be sure that the plastic clip on PCV hose is positioned so that cable clip is beneath hose, and that #1 cable is snapped into this clip to protect it from metal PCV clamp. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Spark Plugs - Intermittent Misfire Spark Plug: Technical Service Bulletins Spark Plugs - Intermittent Misfire NO: 18-10-97 GROUP: Vehicle Performance DATE: Feb. 28, 1997 SUBJECT: Intermittent Single Cylinder Misfire And/Or MIL Illuminated THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-15-96 REV. A DATED JULY 12, 1996 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1996 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-97010). ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE SPECIFIC ENGINE APPLICATIONS FOR FJ MODELS. MODELS: 1995 - 1996 (PL) Neon 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH 2.0L SOHC ENGINE (JA & PL), PRIOR TO JANUARY 2, 1996 (MDH 01-02-XX) AND WITH 2.0L DOHC ENGINE (PL) PRIOR TO APRIL 1, 1996 (MDH 04-01-XX) AND TO ALL 1995 & 1996 FJ **NATURALLY ASPIRATED** 2.0L VEHICLES. SYMPTOM/CONDITION: Intermittent single cylinder misfire as indicated by the Diagnostic Trouble Code (DTC) screen on the DRB III which cannot be readily reproduced. DIAGNOSIS: Follow the diagnostic steps in the 1996 Powertrain Diagnostic Manual for 2.0L/2.4L/2.5L/3.3L/3.5L Electronic Fuel Injection (Publication Number 81-699-95008), pages 417 to 419 (Test 107A). If the diagnostic repair procedure does not repair the problem, proceed to the repair procedure. PARTS REQUIRED: NOTE: IT IS IMPERATIVE THAT THE CHRYSLER PART NUMBER GIVEN BELOW BE REQUESTED WHEN ORDERING. ONLY THE CHRYSLER PART NUMBER WAS CHANGED, THE CHAMPION PART NUMBER DID NOT CHANGE. AR 5269897 Spark Plug, (PL & JA - SOHC & DOHC) AR 5269899 Spark Plug, (FJ- DOHC **Naturally Aspirated**) REPAIR PROCEDURE: This bulletin involves the replacement of the spark plug in the effected cylinder with a new spark plug. 1. Remove the spark plug cable. 2. Remove the spark plug and discard. 3. Install the new spark plug and torque to 28 Nm (20 ft. lbs.). 4. Install the spark plug cable. NOTE: THE FOLLOWING STEP IS REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Spark Plugs - Intermittent Misfire > Page 2292 5. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-17-03-91 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications Spark Plug: Specifications Gap Specifications Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap .............................................................................................................................................. ............................................. 0.033 to 0.038 in Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications > Page 2295 Spark Plug: Specifications Tightening Specifications Spark Plugs ......................................................................................................................................... ................................................ 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Specifications > Page 2296 Spark Plug: Specifications Part Number and Thread Size Type - Champion RC9YC Thread size - 14mm (3/4 in) reach Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2297 Spark Plug: Application and ID Type - Champion RC9YC Thread size - 14mm (3/4 in) reach Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2298 Spark Plug: Description and Operation Resistor spark plugs are used in this engine. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for spark plug diagnosis. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2301 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2302 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2303 Spark Plug: Testing and Inspection Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2304 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2305 clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Heavy Colored Deposits DESCRIPTION: Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on the side facing the intake valve. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap, and reinstall .............................................................................................................................................................. .................................................................................... Normal Operating Conditions NORMAL OPERATING CONDITIONS Normal Operation And Cold(Carbon) Fouling The few deposits present will be probably light tan or slightly gray in color with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000 miles) of operation for non Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2306 platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, have the electrodes filed and regapped, and then reinstalled. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum spark plugs. This would damage the platinum pads which would shorten spark plug life. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit. The rust color deposits can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Oil or Ash Encrusted OIL OR ASH ENCRUSTED Oil Or Ash Encrusted If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of spark plugs. Ash encrusted spark plugs can be cleaned and reused. Premature Electrode Wear - Preignition Damage PREIGNITION DAMAGE Preignition Damage Excessive combustion chamber temperature can cause preignition damage. First, the center electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Other possible causes include ignition timing over-advanced and incorrect spark plug heat range. Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2307 center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Determine if the spark plugs are the correct type, as specified on the VECI label, or if other operating conditions are causing engine overheating. Red, Brown, Yellow or White Deposits - Fuel Additives SCAVENGER DEPOSITS Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed using standard procedures. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and reused. Shiny Yellow Glaze COMBUSTION DEPOSITS A shiny yellow glaze coating on the spark plug insulator is evidence of metallic by-products of fuel combustion, caused by chemical additives in certain fuels. Avoid sudden acceleration with wide open throttle after long periods of low speed driving. Spark plugs with combustion deposits can be cleaned and reused. Spark Plug Inspection ^ Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance Schedules. ^ Spark plugs that have low mileage may be cleaned and reused if not otherwise defective -- SEE Spark Plug Condition. After cleaning, file the center electrode flat with a small point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The spark plug gap is 0.033 to0.038 in. ^ Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Wet Oily Deposits FUEL FOULING A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. White or Gray - Burned or Blistered Insulator SPARK PLUG OVERHEATING Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2308 Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in. per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug overheating. Also check for lean air-fuel mixture. Check the torque value of the plugs to ensure good plug-engine seat contact. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2309 Spark Plug: Adjustments Setting Spark Plug Electrode Gap Fig.2 Setting Spark Plug Electrode Gap Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground -- center electrode. Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap .............................................................................................................................................. ............................................. 0.033 to 0.038 in Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2310 Spark Plug: Service and Repair CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. CAUTION: Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. SPARK PLUG REMOVAL 1. Remove the spark plug using a quality socket with a rubber or foam insert. 2. Inspect the spark plug condition. SPARK PLUG CLEANING Spark plugs that have low mileage may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. SPARK PLUG INSTALLATION 1. To avoid cross threading, start the spark plug into the cylinder head by hand. 2. Tighten spark plugs to 28 Nm (20 ft lb) torque. 3. Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube. 4. Connect coil. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Correct compression pressure is 170-225 psi. Compression pressure should not vary more than 25% from cylinder to cylinder. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2314 Compression Check: Testing and Inspection Perform compression test with engine at normal operating temperature, spark plugs removed and throttle wide open. Standard compression pressure is 170-225 psi. The minimum compression pressure is 100 psi with a maximum variation between highest and lowest cylinders of 25 percent. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments Hydraulic lash adjusters are used; no adjustment is necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions Absolute Pressure Sensor: Technical Service Bulletins Emissions/Engine Controls - Service Manual Revisions NUMBER: 26-06-97E GROUP: Miscellaneous DATE: June, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1996 2.0L, 2.4L, 2.5L, 3.3L, 3.8L Engine Diagnostic Manual - Publication Number 81-699-96104 DESCRIPTION OF CHANGES Engine controls - revisions Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 2323 501A Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 2324 501B Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 2325 501C Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 2326 501D Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 2327 502 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 2328 645 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 2329 645A Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 2330 645B Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation > A/C Clutch Relay Operation A/C Signal: Description and Operation A/C Clutch Relay Operation Theory of Operation: The A/C compressor clutch relay controls the 12 volt source for the A/C clutch. The relay is located in the power distribution center. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the run position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). When A/C is requested, the PCM adjusts the idle speed to accommodate the A/C compressor load on the engine. The PCM grounds the relay control circuit after the PCM receives an A/C request and adjustment of the idle speed has been implemented. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation > A/C Clutch Relay Operation > Page 2336 A/C Signal: Description and Operation Related Trouble Codes and Set Conditions A/C Clutch Relay Circuit Name of Code: A/C Clutch Relay Circuit When Monitored: With the ignition key in the run position and battery voltage above 10 volts. Set Condition: An open or shorted condition is detected in the A/C clutch relay control circuit. Theory of Operation: The A/C compressor clutch relay controls the 12 volt source for the A/C clutch. The relay is located in the power distribution center. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the run position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). When A/C is requested, the PCM adjusts the idle speed to accommodate the A/C compressor load on the engine. The PCM grounds the relay control circuit after the PCM receives an A/C request and adjustment of the idle speed has been implemented. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - Compressor clutch relay control circuit open or shorted - Inoperative circuit driver in powertrain control module A/C Pressure Sensor Volts Too High Name of Code: A/C Pressure Sensor Volts Too High When Monitored: With the ignition on, the engine running, and the A/C relay energized, Set Condition: The A/C pressure sensor signal at PCM cavity 42 goes above 4.9 volts. Theory of Operation: The A/C pressure sensor informs the PCM if the A/C system pressure is too low or too high. This information allows the PCM to determine if it can engage the compressor clutch. If the A/C system pressure is too low, the PCM will not engage the compressor clutch. If the system pressure is too high, the PCM will disengage the compressor clutch and turn on the cooling fans to prevent the compressor head pressure from becoming too high. The sensor provides a signal to PCM cavity 42. The sensor receives a 5-volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. Possible Causes: - Sensor signal open - Sensor internally open - PCM failure - Open sensor ground A/C Pressure Sensor Volts Too Low NAME OF CODE: A/C Pressure Sensor Volts Too Low WHEN MONITORED: With the ignition ON, the engine running, and the A/C relay energized. SET CONDITION: The A/C pressure sensor sensor signal at PCM cavity 42 goes below 0.7 volts. THEORY OF OPERATION: The A/C pressure sensor informs the PCM if the A/C system pressure is too low or too high. This information allows the PCM to determine if it can engage the compressor clutch. If the A/C system pressure is too low, the PCM will not engage the compressor clutch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation > A/C Clutch Relay Operation > Page 2337 - If the system pressure is too high, the PCM will disengage the compressor clutch and turn on the cooling fans to prevent the compressor head pressure from becoming too high. The sensor provides a signal to PCM cavity 42. The sensor receives a 5 volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Sensor signal shorted to ground - Sensor internally shorted - PCM failure Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications MAP Sensor Torque Aluminum Manifold = 3 Nm (30 in lbs) Plastic Manifold = 2 Nm (20 in lbs) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2341 Intake Air Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2342 Intake Air Temperature Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Fig.15 MAP/IAT Sensor-DOHC PURPOSE The intake air temperature sensor measures the temperature of the air as it enters the engine. The sensor supplies one of the inputs the PCM uses to determine injector pulse-width. CONSTRUCTION The MAP/Intake Air Temperature (IAT) sensor, located on the intake manifold, combines the MAP and Intake Air Temperature (IAT) functions into one sensor. CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. Circuit K21 connects to cavity 37 of the PCM connector. From circuit K21 the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor As intake air temperature changes the resistance in the sensor changes causing a change in current draw. The PCM provides ground for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor > Page 2345 Intake Air Temperature Sensor: Description and Operation Intake Air Temp Sensor Voltage High Name of Code: Intake Air Temp Sensor Voltage High When Monitored: With the ignition on and the engine running. Set Condition: The intake air sensor circuit voltage at PCM cavity 37 goes above 4.9 volts. Theory of Operation: The intake air temperature sensor (IAT) is located in the intake manifold where it measures the temperature of the air that is about to enter the combustion chambers. The IAT is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. At high temperatures resistance decreases and the voltage will decrease. This allows the sensor to provide an analog voltage signal to PCM cavity 37. The PCM uses this signal to compensate for changes in air density due to temperature. Possible Causes: - Sensor signal circuit open - Sensor internally open - Sensor ground circuit open - Powertrain control module failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor > Page 2346 Intake Air Temperature Sensor: Description and Operation Intake Air Temp Sensor Voltage Low Name of Code: Intake Air Temp Sensor Voltage Low When Monitored: With the ignition on and the engine running. Set Condition: The intake air sensor circuit voltage at PCM cavity 37 goes below 0.157 volt. Theory of Operation: The intake air temperature sensor (IAT) is located in the intake manifold where it measures the temperature of the air that is about to enter the combustion chambers. The IAT is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. At high temperatures resistance decreases and the voltage will decrease. This allows the sensor to provide an analog voltage signal to PCM cavity 37. The PCM uses this signal to compensate for changes in air density due to temperature. Possible Causes: - Sensor signal circuit shorted to ground - Sensor internally shorted - Powertrain control module failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Intake Air Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2349 Intake Air Temperature Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 2350 Intake Air Temperature Sensor: Service and Repair Map/Intake Air Temperature Sensor Fig. 98 MAP/IAT Sensor-DOHC NOTE: The MAP/IAT sensor attaches to the intake manifold plenum (Fig. 98). Fig. 97 Air Inlet Duct-DOHC REMOVAL 1. Remove air inlet duct wing nut and duct from intake manifold (Fig. 97). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 2351 2. Disconnect the electrical connector from the MAP/IAT sensor. 3. Remove sensor mounting screws. 4. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seals. 2. Tighten mounting screws to 2 Nm (20 in lb) torque for a plastic manifold and 3 Nm (30 in lb) for a aluminum manifold. 3. Attach electrical connector to sensor 4. Install air inlet duct wing nut and duct from intake manifold, insure that the duct does not interfer with ignition cables. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Battery Temp Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2355 Battery Temp Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2356 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > General Description Battery Temperature Sensor: Description and Operation General Description CIRCUIT OPERATION From circuit G31 the battery temperature sensor draws voltage from the Powertrain Control Module (PCM). The sensor is a variable resistor. As battery temperature changes, the resistance in the sensor changes causing a change in current draw. Circuit G31 connects to cavity 52 of the PCM connector. The PCM provides ground for the battery temperature sensor signal (circuit G31) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > General Description > Page 2359 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor Operation Sensor External to the PCM Name of Code: Battery Temp Sensor (BTS) Voltage Either Too High or Too Low When Monitored: With the ignition key on. Set Condition: The PCM senses the voltage from the BTS to be either below 0.5 volts or above 4.9 volts for 3 seconds. Theory of Operation: The battery temp sensor voltage is used by the PCM to determine what the charging system goal should be. The PCM uses that goal to determine the charging output level. The battery temp sensor is external to the PCM. Possible Causes: - Battery temp sensor failure - Open circuit in battery temp sensor signal circuit - Short circuit in battery temp sensor signal circuit - PCM failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Battery Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Description and Operation > Component Description Brake Signal: Description and Operation Component Description PURPOSE When the brake switch is activated, the PCM receives an input indicating that the brakes are being applied. The brake switch is mounted on the brake pedal support bracket. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Description and Operation > Component Description > Page 2367 Brake Signal: Description and Operation Brake Switch Sense Circuit Name of Code: Brake (Stop Lamp) Switch Sense Circuit When Monitored: With engine running. Set Condition: Decel (30 - 0 mph). The PCM monitors the brake switch signal expecting it to be continuously low while the vehicle speed cycles 16 times. The count is reset to zero whenever the brake switch indicates a high signal. Accel (0 - 20 mph): The PCM monitors the brake switch signal expecting it to be high while the following maneuver occurs 16 times. After the vehicle speed increases, the PCM must accumulate 6 seconds while delta throttle voltage is above 0.02 volts. The count is reset to zero whenever the brake switch indicates a low signal. Theory of Operation: The brake switch signal is used to disable speed control by venting the Speed Control (S/C) servo. The brake switch signal is used to disable (3 speed ATX) the part throttle unlock, as well as disabling the vehicle speed sensor diagnostics. The signal from the brake switch is used to enable OBDII purge monitor. It also modifies the stall torque management control. Possible Causes: - Brake switch failure - Switch alignment - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Description and Operation > Page 2368 Brake Signal: Testing and Inspection Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2375 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2376 Camshaft Position Sensor: Locations Camshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2377 Camshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Operation Fig.9 Camshaft Position Sensor-DOHC PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity OPERATION Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 2380 The camshaft position sensor attaches to the rear of the cylinder head (Fig. 9). 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 (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. The sensor also acts as a thrust plate to control camshaft endplay. CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the camshaft position sensor The K7 circuit connects to cavity 44 of the PCM connector. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 33 of the PCM connector. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 2381 Camshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP Trouble Code Name of Code: Intermittent Loss of CMP or CKP When Monitored: During engine running. Set Condition: When the expected cam signal level disagrees with the actual cam signal level. Theory of Operation: After the engine has been started, the powertrain control module maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. Possible INTERMITTENT Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 2382 Camshaft Position Sensor: Description and Operation No Cam Signal at PCM Trouble Code Name of Code: No Cam Signal at PCM When Monitored: During engine cranking, after a number of crank position sensor signals have been detected. Set Condition: Signals are not received from the camshaft position sensor when signals are received from the crankshaft position sensor Theory of Operation: The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. The PCM supplies 8 volts and a sensor ground to the CMP sensor. The camshaft position sensor signal circuit has a 5 volt pull-up from the PCM. The sensor signal is created by a rotating target magnet attached to the rear of the camshaft when the north pole of the magnet passes under the sensor, the signal remains at 5 volts. When the south pole passes under the sensor, the signal drops to 0.3 volt. Possible Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and target magnet - Damaged target magnet - Failed sensor - Failed PCM - Broken timing belt - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2385 Camshaft Position Sensor: Testing and Inspection Failure to Start Test This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2386 Camshaft Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Sensor Replacement Fig. 8 Camshaft Position Sensor Location Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head (Fig. 8). REMOVAL 1. Remove filtered air tube from the throttle body and air cleaner housing. 2. Disconnect electrical connector from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.35 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft (Fig. 35). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 2389 Fig.36 Target Magnet Installation NOTE: The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft (Fig. 36). INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install filtered air tube. Tighten clamps to 3 Nm ±1 (25 in lb ±5) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 2390 Camshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 18 Nm (165 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2394 Engine Coolant Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2395 Engine Coolant Temperature Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2396 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig.13 Engine Coolant Temperature Sensor-DOHC PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the intake manifold next to the thermostat housing (Fig. 13). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine cool and temperature gauge in the instrument cluster on circuit G20. See: Engine, Cooling and Exhaust/Cooling System/Lamps and Indicators Cooling System/Temperature Gauge/Description and Operation From circuit K2 the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics Coolant Temperature Sensor/Switch (For Computer): Component Tests and General Diagnostics Helpful Information The engine coolant temperature sensor is case grounded. The case ground provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Component Testing Fig. 80 Engine Coolant Temperature Sensor Location-DOHC 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 80). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 2399 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.39 Engine Coolant Temperature Sensor-DOHC NOTE: The engine coolant temperature sensor threads into the rear of the cylinder head. New sensors have sealant applied to the threads. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. - Tighten to 18 Nm (165 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2404 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position Sensor Bolts ........................................................................................................ .......................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2405 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2406 Crankshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor-PCM Input Fig. 15 Crankshaft Position Sensor Fig. 14 Timing Reference Notches Fig.6 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60° signature notch (Fig. 14). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 2409 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. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69° before top dead center (BTDC). - The second notch represents 49° BTDC. - The third notch represents 29°. - The last notch in each set represents 9° before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM connector. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 2410 Crankshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP Trouble Code Name of Code: Intermittent Loss of CMP or CKP When Monitored: During engine running. Set Condition: When the expected cam signal level disagrees with the actual cam signal level. Theory of Operation: After the engine has been started, the powertrain control module maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. Possible INTERMITTENT Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 2411 Crankshaft Position Sensor: Description and Operation No Crank Reference Signal at PCM Trouble Code Name of Code: No Crank Reference Signal at PCM When Monitored: During engine cranking, with battery voltage less than 11.5 volts and manifold vacuum present. Set Condition: No signal from the crankshaft position (CKP) sensor during engine cranking or there is a camshaft position sensor signal without a CKP sensor signal. Theory of Operation: The crankshaft position sensor is a hall-effect type sensor used to detect crankshaft speed and position. The PCM supplies 8 volts and a sensor ground to the CKP sensor. The crankshaft position sensor signal circuit has a 5-volt pull-up from the PCM. The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. When there isn't a notch under the sensor, the signal drops to 0.3 volt. Possible Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and crankshaft pulse ring - Damaged crankshaft pulse ring - Failed sensor - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 2414 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 2415 Crankshaft Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig. 12 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 12). 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Crankshaft Position Sensor Bolts torque ....................................................................................................................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2418 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Fig. 3 Data Link Connector Data Link Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2422 Data Link Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2423 Data Link Connector: Description and Operation Fig. 3 Data Link Connector PURPOSE Communication link to Powertrain Control Module (PCM) Technician can access inputs and memory including: - Sensor input values - Diagnostic Trouble Codes (DTC's) stored in memory - Last deactivation cause (i.e.. speed control last shut off by; speed control switch, brake switch or no crank sensor signal). Technician can actuate most PCM output devices. NOTE: Monitoring inputs, reading memory -- other than codes -- and actuating output devices can only be accomplished through the use of a scan tool. SEE Computers and Control System/Testing and Inspection. CIRCUIT OPERATION Circuit A14 supplies battery voltage to the universal data link connector. Circuit A14 originates in the Power Distribution Center (PDC) and connects to a battery fed bus bar. A 20 Amp fuse protects circuit A14. A twisted pair of wires, circuits D1 and D2, from the Airbag Control Module (ACM) connect to the universal data link connector. Ground circuit Z12 splices to two cavities of the data link connector. The Z12 circuit also connects to cavities 10 and 50 of the PCM connector. Circuit D20 connects to cavity 75 of the PCM and to the universal data link connector. Circuit D20 is the SCI receive circuit for the PCM. Circuit D21 connects to cavity 65 of the PCM and to the universal data link connector. Circuit D21 is the SCI transmit circuit for the PCM. The D21 circuit splices to the ABS module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Testing and Inspection > Helpful Information Data Link Connector: Testing and Inspection Helpful Information The grounding point for circuit Z12 is the left side of the radiator closure panel. Circuit Z12 also supplies ground for the PCM high current drivers and has the same termination point as circuit Z11. If the system loses ground for the ganged circuits at the left side radiator closure panel the vehicle will not operate. Check the connection at the ganged ground circuit eyelet. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Testing and Inspection > Helpful Information > Page 2426 Data Link Connector: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Description and Operation EGR Backpressure Transducer: Description and Operation Fig. 1 EGR System Fig. 2 Electronic EGR Transducer (EET) The electronic EGR transducer (EET) contains an electrically operated solenoid and a back-pressure transducer (Fig. 2). The Powertrain Control Module (PCM) operates the solenoid. Exhaust system back-pressure controls the transducer. When exhaust system back-pressure becomes high enough, it fully closes a bleed valve in the transducer. - When the PCM de-energizes the solenoid and back-pressure closes the transducer bleed valve, vacuum flows through the transducer to operate the EGR valve. De-energizing the solenoid, but not fully closing the transducer bleed hole (because of low back-pressure), varies the strength of vacuum applied to the EGR valve. Varying the strength of the vacuum changes the amount of EGR supplied to the engine. This provides the correct amount of exhaust gas recirculation for different operating conditions. This system does not allow EGR at idle. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Description and Operation > Page 2430 EGR Backpressure Transducer: Service and Repair Fig. 1 EGR System NOTE: If the EGR system operates incorrectly, replace the entire EGR valve and transducer together. The EGR valve and Electronic EGR Transducer (EET) are calibrated together. NOTE: The EGR valve and EET attach to the rear of the cylinder head (Fig. 1). REMOVAL 1. Disconnect vacuum supply tube from EET solenoid. 2. Disconnect electrical connector from solenoid. 3. Remove EGR tube to EGR valve screws. 4. Remove EGR valve mounting screws. Remove EGR valve and transducer. 5. Clean gasket surfaces. Discard old gaskets. If necessary, clean EGR passages. INSTALLATION 1. Loosely install EGR valve with new gaskets. 2. Finger tighten EGR tube fasteners. 3. Tighten EGR tube fasteners to 11 Nm (95 in lb) torque. 4. Tightening EGR valve mounting screws to 22 Nm (200 in lb) torque. 5. Connect vacuum supply tube to solenoid. 6. Attach electrical connector to solenoid. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 18-005-01 > Feb > 01 > PCM - OBDII Readiness Code Retention Powertrain Control Module: Customer Interest PCM - OBDII Readiness Code Retention NUMBER: 18-005-01 GROUP: Vehicle Performance DATE: Feb. 16, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-18-97, DATED MAY 9, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: OBDII Readiness Code Retention OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module. MODELS: 1995-1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (LH) Intrepid/Vision/Concorde/LHS 1996 (PL) Neon NOTE: THIS INFORMATION APPLIES TO FEDERAL EMISSION (SALES CODE NAA) AND CALIFORNIA EMISSION (SALES CODE NAE) MODELS BUILT PRIOR TO NOV. 21, 1995 (MDH1121XX) AND ALL 1995 JA MODELS EQUIPPED WITH A 2.0L ENGINE AND MANUAL TRANSAXLE. THE CALIFORNIA EMISSION MODELS ADDRESSED IN THIS BULLETIN WERE SOLD IN THE NORTHEAST STATES. CALIFORNIA MODELS SOLD IN CALIFORNIA WERE ADDRESSED WITH RECALL 678 DATED SEPT. 1996. DISCUSSION: The On Board Diagnostic (OBDII) system includes a monitor called readiness codes. The readiness codes indicate that all OBDII diagnostic tests have been performed and that diagnostic trouble codes (DTC's) can be read. It has been determined that the readiness codes may be cleared upon ignition key "OFF" cycles. Absence of readiness codes may cause owners to fail their emission inspection. To correct this condition, the Powertrain Control Module (PCM) must be reprogrammed. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING WITH CIS CD2075 OR HIGHER 1. Flash the PCM using the MDS2 (Mopar Diagnostic System) and DRBIII(R) (Scan Tool). NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 18-005-01 > Feb > 01 > PCM - OBDII Readiness Code Retention > Page 2439 2. Type the necessary information on the Authorized Software Update Label p/n 04669020 (Fig. 1). Attach the label to the PCM and cover it 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: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 180696 > Feb > 96 > PCM - MIL ON/DTC's 84, 81, 27/9D Set Powertrain Control Module: Customer Interest PCM - MIL ON/DTC's 84, 81, 27/9D Set NO: 18-06-96 GROUP: Vehicle Performance DATE: Feb. 23, 1996 SUBJECT: Malfunction Indicator Light illuminated For Erroneous Hex DTC's 84, 81, 27 And/Or 9D MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 2.0L SOHC AND DOHC ENGINES (AUTOMATIC AND MANUAL TRANSAXLE) BUILT PRIOR TO NOVEMBER 14, 1995 (MDH 11-14-XX) IN THE BELVEDERE ASSEMBLY PLANT (D IN THE 11TH POSITION OF THE VIN) AND NOVEMBER 17, 1995 (MDH 11-17-XX) IN THE TOLUCA ASSEMBLY PLANT (T IN THE 11TH POSITION OF THE VIN). SYMPTOM/CONDITION: The Malfunction Indicator Light (MIL) will be illuminated and the following hex codes (DTC's) may be erroneously set: ^ 84 - TPS voltage does not agree with MAP. ^ 81 - Downstream 02 sensor stays at center. ^ 27 - No change in MAP from start to run. ^ 9D - Intermittent loss of cam or crank position. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If one of the above fault codes are set, verify proper operation as follows: ^ 84 - With key on and engine off, TPS voltage should increase smoothly from less than 1.0 volt at idle to greater than 3.0 volts at WOT. ^ 81 - Rear O2 signal - With the engine warmed up, verify that the rear O2 sensor voltage will read outside the .35 to .65 volt range during a road test, especially during hard deceleration and WOT. ^ 27 - MAP - With key on, check BARO; then start vehicle, verify that vacuum is greater than 4 inches of vacuum. ^ 9D - Cam & Crank - Verify cam and crank are in sync using the DRB III. If the above proper operation is not verified, proceed with the appropriate diagnosis and repair as stated in the Powertrain Diagnostic Procedures Manual prior to performing the software reflash contained in this bulletin. If the above proper operation is verified, proceed with the repair procedure. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 19 OR HIGHER AND TIL CD RELEASE 1099 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves reprogramming (flashing) the PCM with new software (calibrations). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 180696 > Feb > 96 > PCM - MIL ON/DTC's 84, 81, 27/9D Set > Page 2444 5. Use the arrow keys and select PROGRAM VEHICLE CONTROLLER on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-44-95 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-005-01 > Feb > 01 > PCM - OBDII Readiness Code Retention Powertrain Control Module: All Technical Service Bulletins PCM - OBDII Readiness Code Retention NUMBER: 18-005-01 GROUP: Vehicle Performance DATE: Feb. 16, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-18-97, DATED MAY 9, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: OBDII Readiness Code Retention OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module. MODELS: 1995-1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (LH) Intrepid/Vision/Concorde/LHS 1996 (PL) Neon NOTE: THIS INFORMATION APPLIES TO FEDERAL EMISSION (SALES CODE NAA) AND CALIFORNIA EMISSION (SALES CODE NAE) MODELS BUILT PRIOR TO NOV. 21, 1995 (MDH1121XX) AND ALL 1995 JA MODELS EQUIPPED WITH A 2.0L ENGINE AND MANUAL TRANSAXLE. THE CALIFORNIA EMISSION MODELS ADDRESSED IN THIS BULLETIN WERE SOLD IN THE NORTHEAST STATES. CALIFORNIA MODELS SOLD IN CALIFORNIA WERE ADDRESSED WITH RECALL 678 DATED SEPT. 1996. DISCUSSION: The On Board Diagnostic (OBDII) system includes a monitor called readiness codes. The readiness codes indicate that all OBDII diagnostic tests have been performed and that diagnostic trouble codes (DTC's) can be read. It has been determined that the readiness codes may be cleared upon ignition key "OFF" cycles. Absence of readiness codes may cause owners to fail their emission inspection. To correct this condition, the Powertrain Control Module (PCM) must be reprogrammed. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING WITH CIS CD2075 OR HIGHER 1. Flash the PCM using the MDS2 (Mopar Diagnostic System) and DRBIII(R) (Scan Tool). NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-005-01 > Feb > 01 > PCM - OBDII Readiness Code Retention > Page 2450 2. Type the necessary information on the Authorized Software Update Label p/n 04669020 (Fig. 1). Attach the label to the PCM and cover it 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: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 180696 > Feb > 96 > PCM - MIL ON/DTC's 84, 81, 27/9D Set Powertrain Control Module: All Technical Service Bulletins PCM - MIL ON/DTC's 84, 81, 27/9D Set NO: 18-06-96 GROUP: Vehicle Performance DATE: Feb. 23, 1996 SUBJECT: Malfunction Indicator Light illuminated For Erroneous Hex DTC's 84, 81, 27 And/Or 9D MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 2.0L SOHC AND DOHC ENGINES (AUTOMATIC AND MANUAL TRANSAXLE) BUILT PRIOR TO NOVEMBER 14, 1995 (MDH 11-14-XX) IN THE BELVEDERE ASSEMBLY PLANT (D IN THE 11TH POSITION OF THE VIN) AND NOVEMBER 17, 1995 (MDH 11-17-XX) IN THE TOLUCA ASSEMBLY PLANT (T IN THE 11TH POSITION OF THE VIN). SYMPTOM/CONDITION: The Malfunction Indicator Light (MIL) will be illuminated and the following hex codes (DTC's) may be erroneously set: ^ 84 - TPS voltage does not agree with MAP. ^ 81 - Downstream 02 sensor stays at center. ^ 27 - No change in MAP from start to run. ^ 9D - Intermittent loss of cam or crank position. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If one of the above fault codes are set, verify proper operation as follows: ^ 84 - With key on and engine off, TPS voltage should increase smoothly from less than 1.0 volt at idle to greater than 3.0 volts at WOT. ^ 81 - Rear O2 signal - With the engine warmed up, verify that the rear O2 sensor voltage will read outside the .35 to .65 volt range during a road test, especially during hard deceleration and WOT. ^ 27 - MAP - With key on, check BARO; then start vehicle, verify that vacuum is greater than 4 inches of vacuum. ^ 9D - Cam & Crank - Verify cam and crank are in sync using the DRB III. If the above proper operation is not verified, proceed with the appropriate diagnosis and repair as stated in the Powertrain Diagnostic Procedures Manual prior to performing the software reflash contained in this bulletin. If the above proper operation is verified, proceed with the repair procedure. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 19 OR HIGHER AND TIL CD RELEASE 1099 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves reprogramming (flashing) the PCM with new software (calibrations). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 180696 > Feb > 96 > PCM - MIL ON/DTC's 84, 81, 27/9D Set > Page 2455 5. Use the arrow keys and select PROGRAM VEHICLE CONTROLLER on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-44-95 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2456 Powertrain Control Module: Specifications PCM 60-Way Connector Torque = 4 Nm (35 in lb) PCM Mounting Screws = 4 Nm (35 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2457 Fig. 100 Powertrain Control Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2460 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2461 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2462 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2463 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2464 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2465 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2466 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2467 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2468 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2469 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2470 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2471 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2472 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2473 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2474 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2475 Powertrain Control Module: Connector Views Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2476 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2477 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2478 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2479 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2480 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2481 Powertrain Control Module: Service Precautions - Before disconnecting any control module, make sure the ignition is off. Failure to do so could damage the module. - When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. - Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. - Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. - Operation of any type, including idling, should be avoided if engine misfiring occurs. Under this condition, the exhaust system operates at abnormally high temperature, which may cause damage to the catalyst or under-body parts of the vehicle. - Alteration or deterioration of ignition or fuel system, or any type of operating condition which results in engine misfiring must be corrected to avoid overheating the catalytic converter. - Proper maintenance and tune-up, according to manufacturer's specifications, should be made to correct abnormal conditions as soon as possible. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation Powertrain Control Module: Description and Operation Circuit Operation CIRCUIT OPERATION Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to cavity 46 of the Powertrain Control Module (PCM). A 20 Amp fuse in the PDC protects circuit A14. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 2484 Powertrain Control Module: Description and Operation PCM Operation Fig. 100 Powertrain Control Module Fig. 3 Data Link Connector The Powertrain Control Module (PCM) is a digital computer containing a microprocessor (Fig. 2). The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. PCM Inputs: Air Conditioning Controls - Battery Voltage - Battery Temperature Sensor - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Fuel Level Sensor - Ignition Switch (A21) - Intake Air Temperature Sensor - Knock Sensor - Manifold Absolute Pressure (MAP) Sensor - Oxygen Sensors - Power Steering Pressure Switch - SCI Receiver - Speed Control Switches - Throttle Position Sensor - Transmission Park/Neutral Switch (Automatic Transmission) - Vehicle Speed Sensor PCM Outputs: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 2485 - Air Conditioning Clutch Relay - Air Conditioning WOT Relay - Auto Shutdown (ASD) Relay - Charging Indicator Lamp - Data Link Connector - Duty Cycle EVAP Canister Purge Solenoid - EGR Solenoid - Fuel Injectors - Fuel Pump Relay - Generator Field - Idle Air Control Motor - Ignition Coils - Malfunction Indicator (Check Engine) Lamp - Radiator Fan Relay - Speed Control Solenoids - Tachometer - Torque Convertor Clutch Solenoid Based on inputs it receives, the PCM adjusts: Fuel Injector Pulse Width - Idle Speed - Ignition Spark Advance - Ignition Coil Dwell - EVAP Canister Purge Operation. The PCM Regulates: Cooling Fan - Air Conditioning - Speed Control System - Generator Charge Rate -- by Adjusting The Generator Field The PCM Also Performs Diagnostics The PCM adjusts injector pulse width (air-fuel ratio) based on: Battery Voltage - Coolant Temperature - Exhaust Gas Content (Oxygen Sensor) - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Manifold Absolute Pressure - Throttle Position The PCM adjusts ignition timing based on: Coolant Temperature - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Knock Sensor - Manifold Absolute Pressure - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) The PCM also adjusts engine idle speed through the idle air control motor based on: Air Conditioning Sense - Battery Temperature - Battery Voltage - Brake Switch - Coolant Temperature - Engine Speed (crankshaft Position Sensor) - Engine Run Time - Manifold Absolute Pressure - Power Steering Pressure Switch - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) - Vehicle Distance (Speed) ASD and Fuel Pump Relay Control Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 2486 The Auto Shutdown (ASD) and fuel pump relays are mounted externally, but turned on and off by the PCM. Crankshaft Position (Engine Speed) Signal The crankshaft position sensor signal is sent to the PCM. If the PCM does not receive the signal within approximately one second of engine cranking, it deactivates the ASD relay and fuel pump relay When these relays deactivate, power is shut off from the fuel injectors, ignition coils, heating element in the oxygen sensors and the fuel pump. PCM Regulated Output Supply Voltages The PCM contains a voltage converter that changes battery voltage to a regulated 8 volts direct current to power: Camshaft Position Sensor - Crankshaft Position Sensor - Vehicle Speed Sensor The PCM also provides a 5 volt direct current supply for: Manifold Absolute Pressure Sensor - Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 2487 Powertrain Control Module: Description and Operation PCM Related Trouble Code Messages Internal Controller Failure WHEN MONITORED With the ignition ON SET CONDITION There is an EPROM sum check failure at power down. THEORY OF OPERATION This code indicates the EPROM memory may be corrupt. PROBABLE CAUSES - Failed PCM PCM Failure EEPROM Write Denied Unsuccessful attempt to write to an EEPROM location by the PCM. PCM Failure SPI Communications WHEN MONITORED With the ignition ON. SET CONDITION Serial communications inside the controller fail eight times. THEORY OF OPERATION Communication between the microprocessors inside the PCM is needed to operate the total system. - A failure to communicate may cause improper actuation of the solenoids and relays. PROBABLE CAUSES - PCM failure PCM Failure SRI Mile Not Stored Unsuccessful attempt to update EMR mileage in the PCM EEPROM. 5 Volt Supply Output Too Low Name of Code: 5-Volt Supply Output Too Low When Monitored: With the ignition on. Set Condition: The 5-volt supply to the sensors is below 3.5 volts for 4 seconds. Theory of Operation: The powertrain control module maintains a 5-volt supply to the MAP sensor, TP sensor, and A/C pressure sensor. It is critical that the 5-volt supply stays between 4.8 volts and 5.1 volts as this input has a direct effect on the sensors' output voltages. Possible Causes: - Shorted 5-volt supply - Shorted sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview Circuit A14 connects to a bus bar in the PDC that the battery feeds. Circuit A14 powers the Automatic Shut Down (ASD) relay and fuel pump relay The A14 circuit also splices to the data link connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2490 Powertrain Control Module: Component Tests and General Diagnostics Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Page 2491 Powertrain Control Module: Service and Repair Fig. 100 Powertrain Control Module NOTE: The PCM attaches to the inner fender panel next to the washer fluid bottle on the driver side (Fig. 100). REMOVAL 1. Disconnect negative cable from battery 2. Disconnect positive cable from battery. 3. Remove washer bottle neck. 4. Squeeze tabs on Power Distribution Center (PDC) while pulling PDC up to remove it from bracket. - Lay PDC aside to gain access to PCM bracket screws. 5. Remove screws attaching PCM to body. 3. Lift PCM up and disconnect the 2 40-way connector 7. Remove PCM. INSTALLATION 1. Attach the 2 40-way connector to PCM. 2. Install PCM. Tighten mounting screws to 4 Nm (35 in lb) torque. 3. Install PDC by pushing down into brackets. 4. Install washer bottle neck. 5. Connect positive cable to battery. 6. Connect negative cable to battery. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection Fuel Level Sensor: Testing and Inspection Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications IAC Motor-To-Throttle Body Bolts 7 Nm (60 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2498 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2499 Idle Air Control Motor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Idle Air Control Motor Idle Speed/Throttle Actuator - Electronic: Description and Operation Idle Air Control Motor THEORY OF OPERATION: The idle air control (IAC) motor is used by the Powertrain Control Module (PCM) to help regulate idle speed. The motor controls the amount of air allowed to bypass the throttle blade. The PCM controls the motor using four driver circuits to position the stepper motor. CIRCUIT OPERATION The Powertrain Control Module (PCM) operates the Idle Air Control (IAC) motor through 4 circuits K39, K40, K59, and K60. Each circuit connects to separate cavities in the PCM connector. Circuit K39 connects to cavity 57 of the PCM connector. - Circuit K40 connects to cavity 48 of the PCM connector. - Circuit K59 connects to cavity 58 of the PCM connector. - Circuit K60 connects to cavity 49 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Idle Air Control Motor > Page 2502 Idle Speed/Throttle Actuator - Electronic: Description and Operation Related Trouble Codes Idle Air Control Motor Circuits Name of Code: Idle Air Control (IAC) Motor Circuits When Monitored: At key on and battery voltage greater than 11.5 volts. Set Condition: The PCM senses a short to ground or battery voltage on any of the four IAC driver circuits for 2.75 seconds while the IAC motor is active. Theory of Operation: The idle air control motor is used by the PCM to regulate idle speed. The motor controls the amount of air allowed to bypass the throttle blade. The PCM controls the motor using four driver circuits to position the stepper motor. Possible Causes: - Driver circuit shorted to ground - Driver circuit shorted to battery voltage - Driver circuits shorted together - Failed PCM - Shorted AC motor - Connector terminals - Connector wires Target Idle Not Reached Name of Code: Target Idle Not Reached When Monitored: With the engine idling and in Drive if automatic. There must not be a MAP sensor trouble code or a throttle position sensor trouble code. Set Condition: Engine idle is not within 200 rpm above or 100 rpm below target idle for 14 seconds. Three separate failures are required to set a bad trip. Two bad trips are required to set code. Theory of Operation: The Idle Air Control (IAC) motor is used by the PCM to help regulate idle speed. The motor controls the amount of air allowed to bypass the throttle blade. The PCM controls the motor using four driver circuits to position the stepper motor. Possible Causes: - Driver circuit shorted to ground - Driver circuit shorted to battery - Driver circuits shorted together - Failed PCM - Shorted IAC motor - Carbon deposits - Driver circuit open - Connector terminals - Connector wires - Large vacuum leak - Throttle misadjusted (min. airflow RPM wrong) - Throttle not closing reliably Vacuum Leak Found (Idle Air Control Motor Fully Seated) Name of Code: Vacuum Leak Found (Idle Air Control (IAC) Motor Fully Seated) When Monitored: With the engine running. Set Condition: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Idle Air Control Motor > Page 2503 The MAP sensor signal does not correlate to the TP sensor signal. Theory of Operation: The powertrain control module (PCM) monitors the MAP signal as well as the TP sensor signal. The vacuum reading decreases as throttle opening increases proportionally. The PCM compares the two values to verify the relation between the two signals. Possible Causes: - Vacuum leak - Faulty MAP sensor - Faulty TP sensor - Powertrain control module failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Page 2504 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Page 2505 Idle Speed/Throttle Actuator - Electronic: Service and Repair Fig. 95 Servicing Idle Air Control Motor CAUTION: When servicing throttle body components, always reassemble components with new 0-rings and seals where applicable. Never use lubricants on 0-rings or seals, damage may result. If assembly of component is difficult, use water to aid assembly. Use care when removing hoses to prevent damage to hose or hose nipple. REMOVAL 1. Disconnect negative cable from battery 2. Remove electrical connector from idle air control motor and throttle position sensor. 3. Remove the EVAP purge hose from the throttle body. 4. Remove throttle body. 5. Remove idle air control motor mounting screws (Fig. 95). 6. Remove motor from throttle body Ensure the 0-ring is removed with the motor. INSTALLATION 1. The new idle air control motor has a new 0-ring installed on it. - If pintle measures more than 1 inch (25 mm) it must be retracted. - Use the DRB Idle Air Control Motor Open/Close Test to retract the pintle (battery must be connected). 2. Carefully place idle air control motor into throttle body 3. Install mounting screws. Tighten screws to 7 Nm (60 in lb) torque. 4. Install throttle body. 5. Connect electrical connector to idle air control motor and throttle position sensor. 6. Connect the EVAP purge hose to the throttle body nipple. 7. Connect negative cable to battery. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > No CCD Message From Body Control Module Information Bus: Description and Operation No CCD Message From Body Control Module NAME OF CODE: No CCD Message From Body Control Module WHEN MONITORED: Anytime the ignition is ON. SET CONDITION: No CCD messages are received from the BCM for 30 seconds. THEORY OF OPERATION: The PCM and BCM communicate across the CCD bus system. Information is needed from either module to operate their respective systems. POSSIBLE CAUSES: - Open CCD Bus (+) or (-) circuit between the modules. - BCM not powered up - BCM or PCM failure Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > No CCD Message From Body Control Module > Page 2510 Information Bus: Description and Operation No CCD Message From TCM Name of Code: No CCD Messages From TCM When Monitored: With the engine running. Set Condition: No CCD messages are received from the TCM for 10 seconds. Theory of Operation: The PCM and TCM communicate across the CCD bus system. Information is needed from either module to operate their respective systems. Possible Causes: - Open COD bus (+) or (-) circuit between the modules - TCM not powered up - Failed TCM - Failed PCM Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2514 Knock Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2515 Knock Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation Knock Sensor: Description and Operation Knock Sensor Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 24 of the PCM connector. The PCM provides ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation > Page 2518 Knock Sensor: Description and Operation Knock Sensor Circuit Trouble Code Name of Code: Knock Sensor Circuit When Monitored: With the ignition on and the engine running. Set Condition: The knock sensor circuit voltage falls below a minimum value at idle or deceleration, The minimum value is from a look-up table internal to the PCM and is based on engine rpm. The trouble code also sets if the sensor output is above 5.0 volts. Theory of Operation: The knock sensor is mounted on the cylinder block below the intake manifold. The knock sensor is comprised of thin piezo-electric ceramic discs bonded to a metal diaphragm. When engine knock occurs, the diaphragm vibrates along with the piezoelectric discs, producing an electrical signal. The signal is used by the PCM to adjust ignition timing to eliminate the knock condition. Possible Causes: - Sensor signal open - Sensor internally open - PCM failure - Sensor signal circuit shorted to ground - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Helpful Information Knock Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2521 Knock Sensor: Testing and Inspection Component Testing The knock sensor can be tested with a digital voltmeter. Sensor output should be between 80 mV and 4 volts with the engine running between 576 and 2,208 rpm. If the output falls outside of this range a DTC will be set. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2522 Knock Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Page 2523 Knock Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig. 15 Power Distribution Center (PDC) Auto Shutdown Relay The relay is located in the Power Distribution Center (PDC) (Fig. 15). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2527 Auto Shutdown Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Automatic Shut Down Relay Automatic Shut Down (ASD) Relay: Description and Operation Automatic Shut Down Relay Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. CIRCUIT OPERATION The Automatic Shut Down (ASD) relay is located in the Power Distribution Center (PDC). Power for the coil and contact side of the relay is supplied on circuit A14. This circuit is HOT at all times and protected by a 20 Amp fuse located in the PDC. The Powertrain Control Module (PCM) controls the ground path for the coil side of the relay on circuit K51. This circuit connects to cavity 67 of the PCM. When the PCM supplies the ground path on circuit K51 the contacts in the relay CLOSE connecting circuits A14 and A142. The A142 circuit is spliced and supplies power to the generator, fuel injectors, PCM, ignition coil, and heated oxygen sensors. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Automatic Shut Down Relay > Page 2530 Automatic Shut Down (ASD) Relay: Description and Operation Related Trouble Codes and Set Conditions Auto Shutdown Relay Control Circuit Name of Code: Auto Shutdown Relay Control Circuit When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: An open or shorted condition is detected in the auto shutdown relay control circuit. Theory of Operation: The automatic shutdown relay (ASD) controls the 12 volt source to the fuel injectors, ignition coil(s), oxygen sensors, and the generator. The relay is located in the power distribution center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the run position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the run or crank position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the ASD relay control circuit ground. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - Auto shutdown relay control circuit open or shorted - Inoperative circuit driver in powertrain control module - PCM failure - Connector terminals - Connector wires No ASD Relay Output Sensed at PCM Name of Code: No Auto Shutdown (ASD) Relay Output Voltage At PCM When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: No voltage sensed at the powertrain control module when the auto shutdown relay is energized. Theory of Operation: When the ASD relay is energized, the relay contacts connect the fused B(+) circuit to the relay output circuit. The powertrain control module is connected in parallel with the ASD relay output circuit. This connection provides the PCM with a circuit to monitor the ASD relay output state. Whenever the PCM energizes the ASD relay, it checks the feedback circuit to ensure voltage is present at the ASD relay output. If voltage is not present, a trouble code is set. Possible Causes: - ASD relay output circuit open - Fused B(+) circuit open - ASD relay - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 Amp fuse located in the PDC. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 2533 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 2534 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 2535 Automatic Shut Down (ASD) Relay: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams Instrument Panel Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Page 2539 Malfunction Indicator Lamp: Description and Operation Fig.1 Data Link (Diagnostic) Connector OPERATION As a functional test, the Malfunction Indicator Lamp (MIL) illuminates at key-on before engine cranking. Whenever the Powertrain Control Module (PCM) sets a Diagnostic Trouble Code (DTC) that affects vehicle emissions, it illuminates the MIL. If a problem is detected, the PCM sends a message over the CCD Bus to the instrument cluster to illuminate the lamp. The PCM illuminates the MIL only for DTC's that affect vehicle emissions. The MIL stays on continuously when the PCM has entered a Limp-In mode or identified a failed emission component. The MIL remains on until the DTC is erased. Also, the MIL either flashes or illuminates continuously when the PCM detects active engine misfire. Addifionally the PCM may reset (turn off) the MIL when one of the following occur: PCM does not detect the malfunction for 3 consecutive trips (except misfire and Fuel system Monitors). - PCM does not detect a malfuction while performing three successive engine misfire or fuel system tests. The PCM performs these tests while the engine is operating within ±375 RPM of and within 10% of the load of the operating condition at which the malfunction was first detected. CIRCUIT OPERATION The Check Engine lamp (Malfunction Indicator Lamp) illuminates when the ignition switch is in the ON position and prior to starting the vehicle. The lamp will turn off after the vehicle is started. If while the vehicle is running a problem is detected in the engine control system the lamp is illuminated. This is accomplished by the Powertrain Control Module (PCM) grounding the G3 circuit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications Manifold Pressure/Vacuum Sensor: Electrical Specifications The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications > Page 2544 Manifold Pressure/Vacuum Sensor: Mechanical Specifications MAP Sensor Torque Aluminum Manifold = 3 Nm (30 in lbs) Plastic Manifold = 2 Nm (20 in lbs) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2545 Map Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2546 IAT/Map Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure Sensor Fig.15 MAP/IAT Sensor-DOHC OPERATION The PCM supplies 5 volts to the MAP sen son The MAP sensor function converts intake manifold pressure into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage increases proportionately. During cranking, before the engine starts running, the PCM determines atmosphenc air pressure from the MAP sensor voltage. While the engine operates, the PCM determines intake manifold pressure from the MAP sensor voltage. Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and the air/fuel mixture. The MAP/Intake Air Temperature Sensor (MAP/IAT) sensor mounts to the intake manifold. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Manifold Absolute Pressure (MAP) sensor. Circuit K6 connects to cavity 61 of the PCM connector. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity 36 of the PCM connector. The PCM provides ground for the MAP sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor > Page 2549 Manifold Pressure/Vacuum Sensor: Description and Operation Related Trouble Codes & Set Conditions MAP Sensor Voltage Too High NAME OF CODE: MAP Sensor Voltage Too High WHEN MONITORED: With engine RPM above 400 but less than 1500 and the Throttle Position (TP) sensor voltage less than 1.0 volt. SET CONDITION: The manifold Absolute Pressure (MAP) sensor signal voltage is greater than 4.6 volts at start or with the engine running for 1.76 seconds. THEORY OF OPERATION: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to Powertrain Control Module (PCM) cavity 36. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at deep throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 61; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Open 5-volt supply circuit - Sensor open internally - Sensor ground circuit - Sensor signal circuit shorted to voltage - Failed PCM - Connector terminals - Connector wires MAP Sensor Voltage Too Low Name of Code: MAP Sensor Voltage Too Low When Monitored: With engine rpm above 400 but less than 1,500 and the TP sensor voltage less than 1.0 volt. Set Condition: The MAP sensor signal voltage is below 1.2 volts at start, or below 0.02 volt for 1.76 seconds with engine running. Theory of Operation: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to PCM cavity 36. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at deep throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 61; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 43. Possible Causes: - Open 5-volt supply circuit - Signal circuit shorted to ground - Failed sensor - PCM failure - Connector terminals - Connector wires No Change In MAP From Start to Run NAME OF CODE: No Change in MAP From Start to Run WHEN MONITORED: With engine RPM above 400 but less than 1500 and the throttle body at closed throttle. SET CONDITION: Too small a difference is seen between barometric pressure at ignition on and manifold vacuum (engine running) for 1.76 seconds. THEORY OF OPERATION: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor > Page 2550 Powertrain Control Module (PCM) cavity 36. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at deep throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 61; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Restricted or leaking vacuum/pressure to MAP sensor - Ice in sensor or passage - Failed sensor - Failed PCM TPS Voltage Does Not Agree With MAP Name of Code: TPS Voltage Does Not Agree with MAP When Monitored: With the engine running and no MAP sensor or TP sensor trouble codes. Set Condition: The powertrain control module (PCM) performs two separate tests on the TP sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 mph and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 4 continuous seconds. Theory of Operation: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from the PCM. The sensor ground is provided by the PCM. Possible Causes: - Failed powertrain control module - Connector wires - TP sensor failure - Vehicle speed - Mechanical failure - MAP sensor - Connector terminals Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing Manifold Pressure/Vacuum Sensor: Testing and Inspection Component Testing Fig. 82 MAP Sensor Connector CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 1 and 4 (Fig. 82). With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. If OK, go to next step. - If not OK, go to step 3. 2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness condition. Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 43. - If OK, go to next step. - If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 3 and 1 with the key ON. The voltage should be approximately 5 volts ± 0.5V). Five volts (± 0.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor. - If not OK, repair or replace the wire harness as required. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing > Page 2553 Manifold Pressure/Vacuum Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing > Page 2554 Manifold Pressure/Vacuum Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 2555 Manifold Pressure/Vacuum Sensor: Service and Repair Map/Intake Air Temperature Sensor Fig. 98 MAP/IAT Sensor-DOHC NOTE: The MAP/IAT sensor attaches to the intake manifold plenum (Fig. 98). Fig. 97 Air Inlet Duct-DOHC REMOVAL 1. Remove air inlet duct wing nut and duct from intake manifold (Fig. 97). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 2556 2. Disconnect the electrical connector from the MAP/IAT sensor. 3. Remove sensor mounting screws. 4. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seals. 2. Tighten mounting screws to 2 Nm (20 in lb) torque for a plastic manifold and 3 Nm (30 in lb) for a aluminum manifold. 3. Attach electrical connector to sensor 4. Install air inlet duct wing nut and duct from intake manifold, insure that the duct does not interfer with ignition cables. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Upstream and Downstream Heated Oxygen Sensors Torque = 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2562 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2563 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2564 Downstream Oxygen Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2565 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor Oxygen Sensor: Description and Operation Heated Oxygen Sensor CIRCUIT OPERATION Circuit A14 is a bus bar in the Power Distribution Center (PDC), and connects to battery voltage. The contact side of the Automatic Shut Down (ASD) relay connects circuit A14 and circuit A142. A 20 Amp fuse in the PDC protects circuits A14 and A142. Circuit A14 also supplies voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) controls the ground path circuit for the coil side of the ASD relay on circuit K51. Circuit K51 connects to cavity 67 of the PCM connector. Circuit A142 splices to supply voltage for the upstream and downstream heated oxygen sensors. The A142 circuit also splices to cavity 6 of the PCM. The input provided by circuit A142 at cavity 6 tells the PCM that the ASD relay energized. Circuit K41 delivers the signal from the upstream heated oxygen sensor to the PCM. Circuit K41 connects to cavity 30 of the PCM connector. Circuit K141 delivers the signal from the down-stream heated oxygen sensor to the PCM. Circuit K141 connects to cavity 51 of the PCM connector. The PCM provides a ground for the upstream and downstream heated oxygen sensor signals (circuit K41 and K141) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector Circuit Z1 provides ground for the heater circuits in each sensor. Circuit Z1 terminates at the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor > Page 2568 Oxygen Sensor: Description and Operation Related Trouble Codes & Set Conditions Downstream O2 Sensor Heater Failure Name of Code: Downstream O2 Sensor Heater Failure When Monitored: With the ignition key oft, after the engine cools down Set Condition: No sensor output signal is received when the PCM powers up the sensor heater. Theory of Operation: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this 02 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases the downstream oxygen sensor tells the PCM how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. This O2 sensor serves as an indicator of oxygen content. The heater element helps the O2 sensor quickly reach a normal and steady operating temperature, which is required for proper emission control. Possible Causes: - Open heater element circuit - O2 sensor failure - Powertrain control module failure - Connector terminals - Connector wires Downstream O2 Sensor Shorted to Ground Name of Code: Downstream O2S Voltage Shorted To Ground When Monitored: With the ignition key off, after the engine cools down. Set Condition: The downstream oxygen sensor signal voltage is below 0.156 volt prior to O2 sensor heater test. Theory of Operation: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the PCM how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. Variations in the signal from the O2 sensor serve as an indicator of oxygen content. The catalytic converter absorbs the oxygen in the exhaust gas when the fuel/air mixture is lean. The downstream 02 sensor indicates a deficiency of oxygen when the upstream 02 sensor detects an abundance of oxygen and vice versa. Possible Causes: - Sensor output wire shorted to another circuit - Dirty connection causing voltage tracking in connector - O2 sensor failure - Powertrain control module failure - Connector terminals/wires Downstream O2 Sensor Shorted to Voltage Name of Code: Downstream O2 Sensor Shorted To Voltage When Monitored: With the ignition key on. Set Condition: The engine running for more than 2 minutes and coolant temp. above 176°F. The upstream oxygen sensor signal voltage is above 1.2 volts for 2.6 seconds. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor > Page 2569 Theory of Operation: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. Possible Causes: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure - Powertrain control module failure - Connector terminals - Connector wires Downstream O2 Sensor Stays at Center Name of Code: Downstream O2 Sensor Stays At Center When Monitored: With the vehicle engine running for more than two minutes, engine temperature greater than 170°F, in closed loop. Set Condition: If oxygen sensor voltage stays between 0.29 volts and 0.72 volts for 30 seconds, the PCM pulls the sensor voltage to 5.0 volts for 60 seconds and monitors the sensor voltage. If the voltage stays at 5.0 volts, this trouble code will set, indicating no activities. Theory of Operation: Effective control of exhaust emissions is achieved by an oxygen feedback system. The downstream oxygen sensor (O2S), located in the exhaust path, monitors the exhaust emissions. Once the sensor reaches its normal operating temperature of 300°-350° C (572°-662° F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the efficiency of the catalytic converter. The downstream oxygen sensor is monitored for proper response to assure a correct catalytic converter efficiency calculation. A good sensor will indicate a rich condition when at WOT (due to the enriched F/A ratio), and a lean condition when in decel fuel shut-off (due to the lean F/A ratio). Possible Causes: - Sensor output wire open - Dirt/moisture/grease inside connector - Open ground circuit - Oxygen sensor failure - PCM failure Slow Upstream O2 Sensor During Catalyst Monitor Name of Code: Slow Upstream O2 Sensor During Catalyst Monitor When Monitored: With the engine running, coolant greater than 17O°F, open throttle, steady to slightly increasing vehicle speed between 18 MPH and 55 MPH, with a light load on the engine, for a period no less than five minutes. Set Condition: The upstream oxygen sensor signal voltage is switching from below 0.39 volt to above 0.6 volt and back fewer times than required. Theory of Operation: Effective control of exhaust emissions is achieved by an oxygen feedback system, of which the most important element is the upstream oxygen sensor (O2S). which is located in the exhaust path. Once the sensor reaches its normal operating temperature of 30O° to 350°C (572° to 662°F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the fuel injector pulse width, which maintains the optimum 14.7 to 1 air/fuel (A/F) ratio that is required for the catalytic converter to best control exhaust emissions. Response rate is the time required for the sensor to detect changes in the exhaust gas oxygen content; it switches from lean to rich if it is exposed to a richer than optimum A/F mixture, or vice versa. The O2S output voltage ranges from 0 to 1 volt. A good sensor easily generates an output voltage in this range as it is exposed to different oxygen concentrations. To detect a shift in the A/F mixture (lean or rich), the output voltage has to change beyond a threshold value. A malfunctioning sensor could have difficulty changing beyond the thresholds. Possible Causes: - Exhaust leak Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor > Page 2570 - Dirt/moisture/grease inside connector - Fuel contamination - Engine mechanical - Weak upstream O2 sensor with deteriorated catalyst Upstream O2 Sensor Heater Failure Name of Code: Upstream O2 Sensor Heater Failure When Monitored: With the Ignition key off, after the engine cools down. Set Condition: No sensor output signal is received when the PCM powers up the sensor heater. Theory of Operation: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases. the upstream oxygen sensor tells the PCM how well its output signal is controlling the air/fuel ratio. Variations in the signals from the O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/ fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. The heater element helps the 02 sensor quickly reach a normal and steady operating temperature. which is required for proper emission control. Possible Causes: - Open heater element circuit - 02 sensor failure - PCM failure - Dirt/moisture/grease inside connector - 02 sensor heater wires - ASD relay failure Upstream O2 Sensor Shorted to Voltage Name of Code: Upstream 02 Sensor Shorted to Voltage When Monitored: With the ignition key on. Set Condition: The engine running for more than 2 minutes and coolant temperature above 176°F. The upstream oxygen sensor signal voltage is above 1.2 volts for 2.6 seconds. Theory of Operation: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. Possible Causes: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - 02 sensor failure - Powertrain control module failure - Connector terminals - Connector wires Upstream O2 Sensor Slow Response Name of Code: Upstream O2 Sensor Slow Response When Monitored: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor > Page 2571 With the engine running for more than 3 minutes, engine temperature greater than 120°F, after reaching a vehicle speed of 20 mph for 120 seconds, at idle with the transmission in drive (auto) or in neutral (manual). Set Condition: The upstream oxygen sensor signal voltage is switching from below 0.39 volt to above 0.6 volt and back fewer times than required. Theory of Operation: Effective control of exhaust emissions is achieved by an oxygen feedback system, of which the most important element is the upstream oxygen sensor (O2S), which is located in the exhaust path. Once the sensor reaches its normal operating temperature of 300°C-350°C (572°F - 662°F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the fuel injector pulse width, which maintains the optimum 14.7 to 1 air/fuel (A/F) ratio that is required for the catalytic converter to best control exhaust emissions. Response rate is the time required for the sensor to detect changes in the exhaust gas oxygen content; it switches from lean to rich if it is exposed to a richer than optimum A/F mixture, or vice versa. The O2S output voltage ranges from 0 to 1 volt. A good sensor easily generates an output voltage in this range as it is exposed to different oxygen concentrations. To detect a shift in the A/F mixture (lean or rich), the output voltage has to change beyond a threshold value. A malfunctioning sensor could have difficulty changing beyond the thresholds. Possible Causes: - Exhaust leak - Dirt/moisture/grease inside connector - Fuel contamination - Engine mechanical Upstream O2 Sensor Stays at Center Name of Code: Upstream O2 Sensor Stays at Center When Monitored: With the engine running for more than 2 minutes and engine temperature greater than 17O°F. Set Condition: The upstream oxygen sensor signal voltage is between 0.35 volts and 0.55 volts for 1.5 minutes. Theory of Operation: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this 02 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. Possible Causes: - Sensor output wire open - O2 sensor failure - PCM failure - Dirt/moisture/grease causing voltage tracking in connector - Connector wires Upstream O2S Voltage Shorted to Ground Name of Code: Upstream 02S Voltage Shorted To Ground When Monitored: With engine coolant temperature above 170°F on the previous key on, after a cold start, engine coolant below 98°F, and ambient/ battery sensor reading within 27°F of engine coolant. Set Condition: The upstream oxygen sensor signal voltage is below 0.156 volts for 28 seconds after starting engine. Theory of Operation: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from the O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be low, approximately 0.1 volt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor > Page 2572 Possible Causes: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure - Powertrain control module failure - Connector terminals - Connector wires to sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, ASD relay, generator, and the upstream and downstream heated oxygen sensors. The PCM controls the ground circuit for each of the components powered by circuit A142. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2575 Oxygen Sensor: Testing and Inspection Oxygen Sensor Heater Circuit Test NOTE: Use an ohmmeter to test the heating element of the oxygen sensors. 1. Disconnect the electrical connector from each oxygen sensor. - The white wires in the sensor connector are the power and ground circuits for the heater elements. 2. Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. - Replace the heated oxygen sensor if the resistance is not between 4 and 7 ohms. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor Oxygen Sensor: Service and Repair Downstream O2 Sensor Fig. 19 Downstream Heated Oxygen Sensor NOTE: The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic convertor (Fig. 19). REMOVAL 1. Raise vehicle. 2. Disconnect electrical connector from sensor. 3. Disconnect sensor electrical harness from clips along body. Fig. 20 Downstream Heated Oxygen Sensor Removal/Installation 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 20). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 2578 Oxygen Sensor: Service and Repair Upstream O2 Sensor Fig. 18 Upstream Heated Oxygen Sensor Removal/Installation REMOVAL 1. Raise and support vehicle. 2. Unplug sensor connector. 3. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 18). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 2579 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 2584 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2585 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2586 Power Steering Pressure Switch: Description and Operation Fig. 15 Power Steering Pressure Switch PURPOSE On vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. The pressure switch improves vehicle idle quality, by controlling engine idle speed when required. The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed is increased. This increase in engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The power steering pressure switch is mounted directly to the power steering gear on vehicles requiring its usage. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z12 provides ground for the power steering pressure switch. The grounding point for circuit Z12 is the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2587 Power Steering Pressure Switch: Testing and Inspection Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Customer Interest for Powertrain Control Module: > 18-005-01 > Feb > 01 > PCM - OBDII Readiness Code Retention Powertrain Control Module: Customer Interest PCM - OBDII Readiness Code Retention NUMBER: 18-005-01 GROUP: Vehicle Performance DATE: Feb. 16, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-18-97, DATED MAY 9, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: OBDII Readiness Code Retention OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module. MODELS: 1995-1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (LH) Intrepid/Vision/Concorde/LHS 1996 (PL) Neon NOTE: THIS INFORMATION APPLIES TO FEDERAL EMISSION (SALES CODE NAA) AND CALIFORNIA EMISSION (SALES CODE NAE) MODELS BUILT PRIOR TO NOV. 21, 1995 (MDH1121XX) AND ALL 1995 JA MODELS EQUIPPED WITH A 2.0L ENGINE AND MANUAL TRANSAXLE. THE CALIFORNIA EMISSION MODELS ADDRESSED IN THIS BULLETIN WERE SOLD IN THE NORTHEAST STATES. CALIFORNIA MODELS SOLD IN CALIFORNIA WERE ADDRESSED WITH RECALL 678 DATED SEPT. 1996. DISCUSSION: The On Board Diagnostic (OBDII) system includes a monitor called readiness codes. The readiness codes indicate that all OBDII diagnostic tests have been performed and that diagnostic trouble codes (DTC's) can be read. It has been determined that the readiness codes may be cleared upon ignition key "OFF" cycles. Absence of readiness codes may cause owners to fail their emission inspection. To correct this condition, the Powertrain Control Module (PCM) must be reprogrammed. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING WITH CIS CD2075 OR HIGHER 1. Flash the PCM using the MDS2 (Mopar Diagnostic System) and DRBIII(R) (Scan Tool). NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Customer Interest for Powertrain Control Module: > 18-005-01 > Feb > 01 > PCM - OBDII Readiness Code Retention > Page 2597 2. Type the necessary information on the Authorized Software Update Label p/n 04669020 (Fig. 1). Attach the label to the PCM and cover it 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: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Customer Interest for Powertrain Control Module: > 180696 > Feb > 96 > PCM - MIL ON/DTC's 84, 81, 27/9D Set Powertrain Control Module: Customer Interest PCM - MIL ON/DTC's 84, 81, 27/9D Set NO: 18-06-96 GROUP: Vehicle Performance DATE: Feb. 23, 1996 SUBJECT: Malfunction Indicator Light illuminated For Erroneous Hex DTC's 84, 81, 27 And/Or 9D MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 2.0L SOHC AND DOHC ENGINES (AUTOMATIC AND MANUAL TRANSAXLE) BUILT PRIOR TO NOVEMBER 14, 1995 (MDH 11-14-XX) IN THE BELVEDERE ASSEMBLY PLANT (D IN THE 11TH POSITION OF THE VIN) AND NOVEMBER 17, 1995 (MDH 11-17-XX) IN THE TOLUCA ASSEMBLY PLANT (T IN THE 11TH POSITION OF THE VIN). SYMPTOM/CONDITION: The Malfunction Indicator Light (MIL) will be illuminated and the following hex codes (DTC's) may be erroneously set: ^ 84 - TPS voltage does not agree with MAP. ^ 81 - Downstream 02 sensor stays at center. ^ 27 - No change in MAP from start to run. ^ 9D - Intermittent loss of cam or crank position. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If one of the above fault codes are set, verify proper operation as follows: ^ 84 - With key on and engine off, TPS voltage should increase smoothly from less than 1.0 volt at idle to greater than 3.0 volts at WOT. ^ 81 - Rear O2 signal - With the engine warmed up, verify that the rear O2 sensor voltage will read outside the .35 to .65 volt range during a road test, especially during hard deceleration and WOT. ^ 27 - MAP - With key on, check BARO; then start vehicle, verify that vacuum is greater than 4 inches of vacuum. ^ 9D - Cam & Crank - Verify cam and crank are in sync using the DRB III. If the above proper operation is not verified, proceed with the appropriate diagnosis and repair as stated in the Powertrain Diagnostic Procedures Manual prior to performing the software reflash contained in this bulletin. If the above proper operation is verified, proceed with the repair procedure. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 19 OR HIGHER AND TIL CD RELEASE 1099 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves reprogramming (flashing) the PCM with new software (calibrations). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Customer Interest for Powertrain Control Module: > 180696 > Feb > 96 > PCM - MIL ON/DTC's 84, 81, 27/9D Set > Page 2602 5. Use the arrow keys and select PROGRAM VEHICLE CONTROLLER on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-44-95 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-005-01 > Feb > 01 > PCM OBDII Readiness Code Retention Powertrain Control Module: All Technical Service Bulletins PCM - OBDII Readiness Code Retention NUMBER: 18-005-01 GROUP: Vehicle Performance DATE: Feb. 16, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-18-97, DATED MAY 9, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: OBDII Readiness Code Retention OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module. MODELS: 1995-1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (LH) Intrepid/Vision/Concorde/LHS 1996 (PL) Neon NOTE: THIS INFORMATION APPLIES TO FEDERAL EMISSION (SALES CODE NAA) AND CALIFORNIA EMISSION (SALES CODE NAE) MODELS BUILT PRIOR TO NOV. 21, 1995 (MDH1121XX) AND ALL 1995 JA MODELS EQUIPPED WITH A 2.0L ENGINE AND MANUAL TRANSAXLE. THE CALIFORNIA EMISSION MODELS ADDRESSED IN THIS BULLETIN WERE SOLD IN THE NORTHEAST STATES. CALIFORNIA MODELS SOLD IN CALIFORNIA WERE ADDRESSED WITH RECALL 678 DATED SEPT. 1996. DISCUSSION: The On Board Diagnostic (OBDII) system includes a monitor called readiness codes. The readiness codes indicate that all OBDII diagnostic tests have been performed and that diagnostic trouble codes (DTC's) can be read. It has been determined that the readiness codes may be cleared upon ignition key "OFF" cycles. Absence of readiness codes may cause owners to fail their emission inspection. To correct this condition, the Powertrain Control Module (PCM) must be reprogrammed. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING WITH CIS CD2075 OR HIGHER 1. Flash the PCM using the MDS2 (Mopar Diagnostic System) and DRBIII(R) (Scan Tool). NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-005-01 > Feb > 01 > PCM OBDII Readiness Code Retention > Page 2608 2. Type the necessary information on the Authorized Software Update Label p/n 04669020 (Fig. 1). Attach the label to the PCM and cover it 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: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 180696 > Feb > 96 > PCM MIL ON/DTC's 84, 81, 27/9D Set Powertrain Control Module: All Technical Service Bulletins PCM - MIL ON/DTC's 84, 81, 27/9D Set NO: 18-06-96 GROUP: Vehicle Performance DATE: Feb. 23, 1996 SUBJECT: Malfunction Indicator Light illuminated For Erroneous Hex DTC's 84, 81, 27 And/Or 9D MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 2.0L SOHC AND DOHC ENGINES (AUTOMATIC AND MANUAL TRANSAXLE) BUILT PRIOR TO NOVEMBER 14, 1995 (MDH 11-14-XX) IN THE BELVEDERE ASSEMBLY PLANT (D IN THE 11TH POSITION OF THE VIN) AND NOVEMBER 17, 1995 (MDH 11-17-XX) IN THE TOLUCA ASSEMBLY PLANT (T IN THE 11TH POSITION OF THE VIN). SYMPTOM/CONDITION: The Malfunction Indicator Light (MIL) will be illuminated and the following hex codes (DTC's) may be erroneously set: ^ 84 - TPS voltage does not agree with MAP. ^ 81 - Downstream 02 sensor stays at center. ^ 27 - No change in MAP from start to run. ^ 9D - Intermittent loss of cam or crank position. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBIII) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. If one of the above fault codes are set, verify proper operation as follows: ^ 84 - With key on and engine off, TPS voltage should increase smoothly from less than 1.0 volt at idle to greater than 3.0 volts at WOT. ^ 81 - Rear O2 signal - With the engine warmed up, verify that the rear O2 sensor voltage will read outside the .35 to .65 volt range during a road test, especially during hard deceleration and WOT. ^ 27 - MAP - With key on, check BARO; then start vehicle, verify that vacuum is greater than 4 inches of vacuum. ^ 9D - Cam & Crank - Verify cam and crank are in sync using the DRB III. If the above proper operation is not verified, proceed with the appropriate diagnosis and repair as stated in the Powertrain Diagnostic Procedures Manual prior to performing the software reflash contained in this bulletin. If the above proper operation is verified, proceed with the repair procedure. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 19 OR HIGHER AND TIL CD RELEASE 1099 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves reprogramming (flashing) the PCM with new software (calibrations). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 180696 > Feb > 96 > PCM MIL ON/DTC's 84, 81, 27/9D Set > Page 2613 5. Use the arrow keys and select PROGRAM VEHICLE CONTROLLER on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-44-95 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2614 Powertrain Control Module: Specifications PCM 60-Way Connector Torque = 4 Nm (35 in lb) PCM Mounting Screws = 4 Nm (35 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2615 Fig. 100 Powertrain Control Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2618 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2619 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2620 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2621 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2622 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2623 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2624 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2625 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2626 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2627 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2628 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2629 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2630 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2631 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2632 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2633 Powertrain Control Module: Connector Views Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2634 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2635 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2636 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2637 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2638 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2639 Powertrain Control Module: Service Precautions - Before disconnecting any control module, make sure the ignition is off. Failure to do so could damage the module. - When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. - Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. - Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. - Operation of any type, including idling, should be avoided if engine misfiring occurs. Under this condition, the exhaust system operates at abnormally high temperature, which may cause damage to the catalyst or under-body parts of the vehicle. - Alteration or deterioration of ignition or fuel system, or any type of operating condition which results in engine misfiring must be corrected to avoid overheating the catalytic converter. - Proper maintenance and tune-up, according to manufacturer's specifications, should be made to correct abnormal conditions as soon as possible. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation Powertrain Control Module: Description and Operation Circuit Operation CIRCUIT OPERATION Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to cavity 46 of the Powertrain Control Module (PCM). A 20 Amp fuse in the PDC protects circuit A14. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 2642 Powertrain Control Module: Description and Operation PCM Operation Fig. 100 Powertrain Control Module Fig. 3 Data Link Connector The Powertrain Control Module (PCM) is a digital computer containing a microprocessor (Fig. 2). The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. PCM Inputs: Air Conditioning Controls - Battery Voltage - Battery Temperature Sensor - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Fuel Level Sensor - Ignition Switch (A21) - Intake Air Temperature Sensor - Knock Sensor - Manifold Absolute Pressure (MAP) Sensor - Oxygen Sensors - Power Steering Pressure Switch - SCI Receiver - Speed Control Switches - Throttle Position Sensor - Transmission Park/Neutral Switch (Automatic Transmission) - Vehicle Speed Sensor PCM Outputs: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 2643 - Air Conditioning Clutch Relay - Air Conditioning WOT Relay - Auto Shutdown (ASD) Relay - Charging Indicator Lamp - Data Link Connector - Duty Cycle EVAP Canister Purge Solenoid - EGR Solenoid - Fuel Injectors - Fuel Pump Relay - Generator Field - Idle Air Control Motor - Ignition Coils - Malfunction Indicator (Check Engine) Lamp - Radiator Fan Relay - Speed Control Solenoids - Tachometer - Torque Convertor Clutch Solenoid Based on inputs it receives, the PCM adjusts: Fuel Injector Pulse Width - Idle Speed - Ignition Spark Advance - Ignition Coil Dwell - EVAP Canister Purge Operation. The PCM Regulates: Cooling Fan - Air Conditioning - Speed Control System - Generator Charge Rate -- by Adjusting The Generator Field The PCM Also Performs Diagnostics The PCM adjusts injector pulse width (air-fuel ratio) based on: Battery Voltage - Coolant Temperature - Exhaust Gas Content (Oxygen Sensor) - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Manifold Absolute Pressure - Throttle Position The PCM adjusts ignition timing based on: Coolant Temperature - Engine Speed (Crankshaft Position Sensor) - Intake Air Temperature - Knock Sensor - Manifold Absolute Pressure - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) The PCM also adjusts engine idle speed through the idle air control motor based on: Air Conditioning Sense - Battery Temperature - Battery Voltage - Brake Switch - Coolant Temperature - Engine Speed (crankshaft Position Sensor) - Engine Run Time - Manifold Absolute Pressure - Power Steering Pressure Switch - Throttle Position - Transmission Gear Selection (Park/Neutral Switch) - Vehicle Distance (Speed) ASD and Fuel Pump Relay Control Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 2644 The Auto Shutdown (ASD) and fuel pump relays are mounted externally, but turned on and off by the PCM. Crankshaft Position (Engine Speed) Signal The crankshaft position sensor signal is sent to the PCM. If the PCM does not receive the signal within approximately one second of engine cranking, it deactivates the ASD relay and fuel pump relay When these relays deactivate, power is shut off from the fuel injectors, ignition coils, heating element in the oxygen sensors and the fuel pump. PCM Regulated Output Supply Voltages The PCM contains a voltage converter that changes battery voltage to a regulated 8 volts direct current to power: Camshaft Position Sensor - Crankshaft Position Sensor - Vehicle Speed Sensor The PCM also provides a 5 volt direct current supply for: Manifold Absolute Pressure Sensor - Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Circuit Operation > Page 2645 Powertrain Control Module: Description and Operation PCM Related Trouble Code Messages Internal Controller Failure WHEN MONITORED With the ignition ON SET CONDITION There is an EPROM sum check failure at power down. THEORY OF OPERATION This code indicates the EPROM memory may be corrupt. PROBABLE CAUSES - Failed PCM PCM Failure EEPROM Write Denied Unsuccessful attempt to write to an EEPROM location by the PCM. PCM Failure SPI Communications WHEN MONITORED With the ignition ON. SET CONDITION Serial communications inside the controller fail eight times. THEORY OF OPERATION Communication between the microprocessors inside the PCM is needed to operate the total system. - A failure to communicate may cause improper actuation of the solenoids and relays. PROBABLE CAUSES - PCM failure PCM Failure SRI Mile Not Stored Unsuccessful attempt to update EMR mileage in the PCM EEPROM. 5 Volt Supply Output Too Low Name of Code: 5-Volt Supply Output Too Low When Monitored: With the ignition on. Set Condition: The 5-volt supply to the sensors is below 3.5 volts for 4 seconds. Theory of Operation: The powertrain control module maintains a 5-volt supply to the MAP sensor, TP sensor, and A/C pressure sensor. It is critical that the 5-volt supply stays between 4.8 volts and 5.1 volts as this input has a direct effect on the sensors' output voltages. Possible Causes: - Shorted 5-volt supply - Shorted sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview Circuit A14 connects to a bus bar in the PDC that the battery feeds. Circuit A14 powers the Automatic Shut Down (ASD) relay and fuel pump relay The A14 circuit also splices to the data link connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2648 Powertrain Control Module: Component Tests and General Diagnostics Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Page 2649 Powertrain Control Module: Service and Repair Fig. 100 Powertrain Control Module NOTE: The PCM attaches to the inner fender panel next to the washer fluid bottle on the driver side (Fig. 100). REMOVAL 1. Disconnect negative cable from battery 2. Disconnect positive cable from battery. 3. Remove washer bottle neck. 4. Squeeze tabs on Power Distribution Center (PDC) while pulling PDC up to remove it from bracket. - Lay PDC aside to gain access to PCM bracket screws. 5. Remove screws attaching PCM to body. 3. Lift PCM up and disconnect the 2 40-way connector 7. Remove PCM. INSTALLATION 1. Attach the 2 40-way connector to PCM. 2. Install PCM. Tighten mounting screws to 4 Nm (35 in lb) torque. 3. Install PDC by pushing down into brackets. 4. Install washer bottle neck. 5. Connect positive cable to battery. 6. Connect negative cable to battery. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig. 15 Power Distribution Center (PDC) Auto Shutdown Relay The relay is located in the Power Distribution Center (PDC) (Fig. 15). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2653 Auto Shutdown Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Automatic Shut Down Relay Automatic Shut Down (ASD) Relay: Description and Operation Automatic Shut Down Relay Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. CIRCUIT OPERATION The Automatic Shut Down (ASD) relay is located in the Power Distribution Center (PDC). Power for the coil and contact side of the relay is supplied on circuit A14. This circuit is HOT at all times and protected by a 20 Amp fuse located in the PDC. The Powertrain Control Module (PCM) controls the ground path for the coil side of the relay on circuit K51. This circuit connects to cavity 67 of the PCM. When the PCM supplies the ground path on circuit K51 the contacts in the relay CLOSE connecting circuits A14 and A142. The A142 circuit is spliced and supplies power to the generator, fuel injectors, PCM, ignition coil, and heated oxygen sensors. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Automatic Shut Down Relay > Page 2656 Automatic Shut Down (ASD) Relay: Description and Operation Related Trouble Codes and Set Conditions Auto Shutdown Relay Control Circuit Name of Code: Auto Shutdown Relay Control Circuit When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: An open or shorted condition is detected in the auto shutdown relay control circuit. Theory of Operation: The automatic shutdown relay (ASD) controls the 12 volt source to the fuel injectors, ignition coil(s), oxygen sensors, and the generator. The relay is located in the power distribution center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the run position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the run or crank position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the ASD relay control circuit ground. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - Auto shutdown relay control circuit open or shorted - Inoperative circuit driver in powertrain control module - PCM failure - Connector terminals - Connector wires No ASD Relay Output Sensed at PCM Name of Code: No Auto Shutdown (ASD) Relay Output Voltage At PCM When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: No voltage sensed at the powertrain control module when the auto shutdown relay is energized. Theory of Operation: When the ASD relay is energized, the relay contacts connect the fused B(+) circuit to the relay output circuit. The powertrain control module is connected in parallel with the ASD relay output circuit. This connection provides the PCM with a circuit to monitor the ASD relay output state. Whenever the PCM energizes the ASD relay, it checks the feedback circuit to ensure voltage is present at the ASD relay output. If voltage is not present, a trouble code is set. Possible Causes: - ASD relay output circuit open - Fused B(+) circuit open - ASD relay - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 Amp fuse located in the PDC. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 2659 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 2660 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 2661 Automatic Shut Down (ASD) Relay: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions Absolute Pressure Sensor: Technical Service Bulletins Emissions/Engine Controls - Service Manual Revisions NUMBER: 26-06-97E GROUP: Miscellaneous DATE: June, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1996 2.0L, 2.4L, 2.5L, 3.3L, 3.8L Engine Diagnostic Manual - Publication Number 81-699-96104 DESCRIPTION OF CHANGES Engine controls - revisions Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 2667 501A Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 2668 501B Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 2669 501C Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 2670 501D Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 2671 502 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 2672 645 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 2673 645A Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Service Manual Revisions > Page 2674 645B Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Battery Temp Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2678 Battery Temp Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2679 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > General Description Battery Temperature Sensor: Description and Operation General Description CIRCUIT OPERATION From circuit G31 the battery temperature sensor draws voltage from the Powertrain Control Module (PCM). The sensor is a variable resistor. As battery temperature changes, the resistance in the sensor changes causing a change in current draw. Circuit G31 connects to cavity 52 of the PCM connector. The PCM provides ground for the battery temperature sensor signal (circuit G31) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > General Description > Page 2682 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor Operation Sensor External to the PCM Name of Code: Battery Temp Sensor (BTS) Voltage Either Too High or Too Low When Monitored: With the ignition key on. Set Condition: The PCM senses the voltage from the BTS to be either below 0.5 volts or above 4.9 volts for 3 seconds. Theory of Operation: The battery temp sensor voltage is used by the PCM to determine what the charging system goal should be. The PCM uses that goal to determine the charging output level. The battery temp sensor is external to the PCM. Possible Causes: - Battery temp sensor failure - Open circuit in battery temp sensor signal circuit - Short circuit in battery temp sensor signal circuit - PCM failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Battery Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2691 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2692 Camshaft Position Sensor: Locations Camshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2693 Camshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Operation Fig.9 Camshaft Position Sensor-DOHC PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity OPERATION Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 2696 The camshaft position sensor attaches to the rear of the cylinder head (Fig. 9). 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 (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. The sensor also acts as a thrust plate to control camshaft endplay. CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the camshaft position sensor The K7 circuit connects to cavity 44 of the PCM connector. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 33 of the PCM connector. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 2697 Camshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP Trouble Code Name of Code: Intermittent Loss of CMP or CKP When Monitored: During engine running. Set Condition: When the expected cam signal level disagrees with the actual cam signal level. Theory of Operation: After the engine has been started, the powertrain control module maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. Possible INTERMITTENT Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 2698 Camshaft Position Sensor: Description and Operation No Cam Signal at PCM Trouble Code Name of Code: No Cam Signal at PCM When Monitored: During engine cranking, after a number of crank position sensor signals have been detected. Set Condition: Signals are not received from the camshaft position sensor when signals are received from the crankshaft position sensor Theory of Operation: The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. The PCM supplies 8 volts and a sensor ground to the CMP sensor. The camshaft position sensor signal circuit has a 5 volt pull-up from the PCM. The sensor signal is created by a rotating target magnet attached to the rear of the camshaft when the north pole of the magnet passes under the sensor, the signal remains at 5 volts. When the south pole passes under the sensor, the signal drops to 0.3 volt. Possible Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and target magnet - Damaged target magnet - Failed sensor - Failed PCM - Broken timing belt - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2701 Camshaft Position Sensor: Testing and Inspection Failure to Start Test This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2702 Camshaft Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Sensor Replacement Fig. 8 Camshaft Position Sensor Location Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head (Fig. 8). REMOVAL 1. Remove filtered air tube from the throttle body and air cleaner housing. 2. Disconnect electrical connector from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.35 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft (Fig. 35). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 2705 Fig.36 Target Magnet Installation NOTE: The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft (Fig. 36). INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install filtered air tube. Tighten clamps to 3 Nm ±1 (25 in lb ±5) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 2706 Camshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 18 Nm (165 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2710 Engine Coolant Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2711 Engine Coolant Temperature Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2712 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig.13 Engine Coolant Temperature Sensor-DOHC PURPOSE The combination coolant temperature sensor has two elements. One element supplies coolant temperature signal to the PCM. - The other element supplies coolant temperature signal to the instrument panel gauge cluster. The PCM determines engine coolant temperature from the coolant temperature sensor. OPERATION As coolant temperature varies the coolant temperature sensors resistance changes resulting in a different input voltage to the PCM and the instrument panel gauge cluster. When the engine is cold, the PCM will provide slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The coolant sensor threads into the intake manifold next to the thermostat housing (Fig. 13). New sensors have sealant applied to the threads. CIRCUIT OPERATION The engine coolant temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. The sensor also operates the engine cool and temperature gauge in the instrument cluster on circuit G20. See: Engine, Cooling and Exhaust/Cooling System/Lamps and Indicators Cooling System/Temperature Gauge/Description and Operation From circuit K2 the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes causing a change in current draw. The K2 circuit connects to cavity 26 of the PCM connector. The PCM provides ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Tests and General Diagnostics Coolant Temperature Sensor/Switch (For Computer): Component Tests and General Diagnostics Helpful Information The engine coolant temperature sensor is case grounded. The case ground provides the ground for the coolant temperature gauge circuit G20. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Component Testing Fig. 80 Engine Coolant Temperature Sensor Location-DOHC 1. With the key off, disconnect wire harness connector from coolant temperature sensor (Fig. 80). Fig. 27 Engine Coolant Temperature Sensor 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 27). The ohmmeter should read as follows: - Engine/Sensor at normal operating temperature around 200°F should read approximately 700 to 1,000 ohms. - Engine/Sensor at room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM 60-way connector terminal 28 and the sensor harness connector. Also check for continuity between PCM 60-way connector terminal 51 and the sensor harness connector. Refer to electrical diagrams for circuit information. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 2715 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig.39 Engine Coolant Temperature Sensor-DOHC NOTE: The engine coolant temperature sensor threads into the rear of the cylinder head. New sensors have sealant applied to the threads. REMOVAL 1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant sensor electrical connector. 3. Remove coolant sensor. INSTALLATION 1. Install coolant sensor. - Tighten to 18 Nm (165 in lb) torque. 2. Attach electrical connector to sensor. 3. Fill cooling system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2720 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position Sensor Bolts ........................................................................................................ .......................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2721 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2722 Crankshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor-PCM Input Fig. 15 Crankshaft Position Sensor Fig. 14 Timing Reference Notches Fig.6 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60° signature notch (Fig. 14). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 2725 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. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69° before top dead center (BTDC). - The second notch represents 49° BTDC. - The third notch represents 29°. - The last notch in each set represents 9° before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM connector. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 2726 Crankshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP Trouble Code Name of Code: Intermittent Loss of CMP or CKP When Monitored: During engine running. Set Condition: When the expected cam signal level disagrees with the actual cam signal level. Theory of Operation: After the engine has been started, the powertrain control module maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. Possible INTERMITTENT Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 2727 Crankshaft Position Sensor: Description and Operation No Crank Reference Signal at PCM Trouble Code Name of Code: No Crank Reference Signal at PCM When Monitored: During engine cranking, with battery voltage less than 11.5 volts and manifold vacuum present. Set Condition: No signal from the crankshaft position (CKP) sensor during engine cranking or there is a camshaft position sensor signal without a CKP sensor signal. Theory of Operation: The crankshaft position sensor is a hall-effect type sensor used to detect crankshaft speed and position. The PCM supplies 8 volts and a sensor ground to the CKP sensor. The crankshaft position sensor signal circuit has a 5-volt pull-up from the PCM. The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. When there isn't a notch under the sensor, the signal drops to 0.3 volt. Possible Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and crankshaft pulse ring - Damaged crankshaft pulse ring - Failed sensor - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 2730 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 2731 Crankshaft Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig. 12 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 12). 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Crankshaft Position Sensor Bolts torque ....................................................................................................................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 2734 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Testing and Inspection Fuel Level Sensor: Testing and Inspection Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications MAP Sensor Torque Aluminum Manifold = 3 Nm (30 in lbs) Plastic Manifold = 2 Nm (20 in lbs) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2741 Intake Air Temperature Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2742 Intake Air Temperature Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Fig.15 MAP/IAT Sensor-DOHC PURPOSE The intake air temperature sensor measures the temperature of the air as it enters the engine. The sensor supplies one of the inputs the PCM uses to determine injector pulse-width. CONSTRUCTION The MAP/Intake Air Temperature (IAT) sensor, located on the intake manifold, combines the MAP and Intake Air Temperature (IAT) functions into one sensor. CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. Circuit K21 connects to cavity 37 of the PCM connector. From circuit K21 the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor As intake air temperature changes the resistance in the sensor changes causing a change in current draw. The PCM provides ground for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor > Page 2745 Intake Air Temperature Sensor: Description and Operation Intake Air Temp Sensor Voltage High Name of Code: Intake Air Temp Sensor Voltage High When Monitored: With the ignition on and the engine running. Set Condition: The intake air sensor circuit voltage at PCM cavity 37 goes above 4.9 volts. Theory of Operation: The intake air temperature sensor (IAT) is located in the intake manifold where it measures the temperature of the air that is about to enter the combustion chambers. The IAT is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. At high temperatures resistance decreases and the voltage will decrease. This allows the sensor to provide an analog voltage signal to PCM cavity 37. The PCM uses this signal to compensate for changes in air density due to temperature. Possible Causes: - Sensor signal circuit open - Sensor internally open - Sensor ground circuit open - Powertrain control module failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor > Page 2746 Intake Air Temperature Sensor: Description and Operation Intake Air Temp Sensor Voltage Low Name of Code: Intake Air Temp Sensor Voltage Low When Monitored: With the ignition on and the engine running. Set Condition: The intake air sensor circuit voltage at PCM cavity 37 goes below 0.157 volt. Theory of Operation: The intake air temperature sensor (IAT) is located in the intake manifold where it measures the temperature of the air that is about to enter the combustion chambers. The IAT is a negative temperature coefficient (NTC) thermistor-type sensor (resistance varies inversely with temperature). This means at cold temperatures its resistance is high so the voltage signal will be high. At high temperatures resistance decreases and the voltage will decrease. This allows the sensor to provide an analog voltage signal to PCM cavity 37. The PCM uses this signal to compensate for changes in air density due to temperature. Possible Causes: - Sensor signal circuit shorted to ground - Sensor internally shorted - Powertrain control module failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Intake Air Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2749 Intake Air Temperature Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 2750 Intake Air Temperature Sensor: Service and Repair Map/Intake Air Temperature Sensor Fig. 98 MAP/IAT Sensor-DOHC NOTE: The MAP/IAT sensor attaches to the intake manifold plenum (Fig. 98). Fig. 97 Air Inlet Duct-DOHC REMOVAL 1. Remove air inlet duct wing nut and duct from intake manifold (Fig. 97). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 2751 2. Disconnect the electrical connector from the MAP/IAT sensor. 3. Remove sensor mounting screws. 4. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seals. 2. Tighten mounting screws to 2 Nm (20 in lb) torque for a plastic manifold and 3 Nm (30 in lb) for a aluminum manifold. 3. Attach electrical connector to sensor 4. Install air inlet duct wing nut and duct from intake manifold, insure that the duct does not interfer with ignition cables. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2755 Knock Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2756 Knock Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation Knock Sensor: Description and Operation Knock Sensor Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 24 of the PCM connector. The PCM provides ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation > Page 2759 Knock Sensor: Description and Operation Knock Sensor Circuit Trouble Code Name of Code: Knock Sensor Circuit When Monitored: With the ignition on and the engine running. Set Condition: The knock sensor circuit voltage falls below a minimum value at idle or deceleration, The minimum value is from a look-up table internal to the PCM and is based on engine rpm. The trouble code also sets if the sensor output is above 5.0 volts. Theory of Operation: The knock sensor is mounted on the cylinder block below the intake manifold. The knock sensor is comprised of thin piezo-electric ceramic discs bonded to a metal diaphragm. When engine knock occurs, the diaphragm vibrates along with the piezoelectric discs, producing an electrical signal. The signal is used by the PCM to adjust ignition timing to eliminate the knock condition. Possible Causes: - Sensor signal open - Sensor internally open - PCM failure - Sensor signal circuit shorted to ground - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Helpful Information Knock Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2762 Knock Sensor: Testing and Inspection Component Testing The knock sensor can be tested with a digital voltmeter. Sensor output should be between 80 mV and 4 volts with the engine running between 576 and 2,208 rpm. If the output falls outside of this range a DTC will be set. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2763 Knock Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Page 2764 Knock Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications Manifold Pressure/Vacuum Sensor: Electrical Specifications The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at open throttle when the manifold vacuum is low. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Electrical Specifications > Page 2769 Manifold Pressure/Vacuum Sensor: Mechanical Specifications MAP Sensor Torque Aluminum Manifold = 3 Nm (30 in lbs) Plastic Manifold = 2 Nm (20 in lbs) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2770 Map Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2771 IAT/Map Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Absolute Pressure Sensor Fig.15 MAP/IAT Sensor-DOHC OPERATION The PCM supplies 5 volts to the MAP sen son The MAP sensor function converts intake manifold pressure into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage increases proportionately. During cranking, before the engine starts running, the PCM determines atmosphenc air pressure from the MAP sensor voltage. While the engine operates, the PCM determines intake manifold pressure from the MAP sensor voltage. Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and the air/fuel mixture. The MAP/Intake Air Temperature Sensor (MAP/IAT) sensor mounts to the intake manifold. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Manifold Absolute Pressure (MAP) sensor. Circuit K6 connects to cavity 61 of the PCM connector. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity 36 of the PCM connector. The PCM provides ground for the MAP sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor > Page 2774 Manifold Pressure/Vacuum Sensor: Description and Operation Related Trouble Codes & Set Conditions MAP Sensor Voltage Too High NAME OF CODE: MAP Sensor Voltage Too High WHEN MONITORED: With engine RPM above 400 but less than 1500 and the Throttle Position (TP) sensor voltage less than 1.0 volt. SET CONDITION: The manifold Absolute Pressure (MAP) sensor signal voltage is greater than 4.6 volts at start or with the engine running for 1.76 seconds. THEORY OF OPERATION: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to Powertrain Control Module (PCM) cavity 36. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at deep throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 61; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Open 5-volt supply circuit - Sensor open internally - Sensor ground circuit - Sensor signal circuit shorted to voltage - Failed PCM - Connector terminals - Connector wires MAP Sensor Voltage Too Low Name of Code: MAP Sensor Voltage Too Low When Monitored: With engine rpm above 400 but less than 1,500 and the TP sensor voltage less than 1.0 volt. Set Condition: The MAP sensor signal voltage is below 1.2 volts at start, or below 0.02 volt for 1.76 seconds with engine running. Theory of Operation: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to PCM cavity 36. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at deep throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 61; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 43. Possible Causes: - Open 5-volt supply circuit - Signal circuit shorted to ground - Failed sensor - PCM failure - Connector terminals - Connector wires No Change In MAP From Start to Run NAME OF CODE: No Change in MAP From Start to Run WHEN MONITORED: With engine RPM above 400 but less than 1500 and the throttle body at closed throttle. SET CONDITION: Too small a difference is seen between barometric pressure at ignition on and manifold vacuum (engine running) for 1.76 seconds. THEORY OF OPERATION: This sensor measures manifold absolute pressure and ambient barometric pressure within the manifold. It provides a 0 to 5-volt signal to Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Absolute Pressure Sensor > Page 2775 Powertrain Control Module (PCM) cavity 36. The MAP sensor puts out a low voltage signal (0.5 to 1.8 volts) at idle when the manifold vacuum is high, and a higher voltage signal (3.9 to 4.8 volts) at deep throttle when the manifold vacuum is low. The MAP receives a 5-volt supply from PCM cavity 61; voltage may vary from 4.8 to 5.1 volts. The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Restricted or leaking vacuum/pressure to MAP sensor - Ice in sensor or passage - Failed sensor - Failed PCM TPS Voltage Does Not Agree With MAP Name of Code: TPS Voltage Does Not Agree with MAP When Monitored: With the engine running and no MAP sensor or TP sensor trouble codes. Set Condition: The powertrain control module (PCM) performs two separate tests on the TP sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 mph and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 4 continuous seconds. Theory of Operation: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from the PCM. The sensor ground is provided by the PCM. Possible Causes: - Failed powertrain control module - Connector wires - TP sensor failure - Vehicle speed - Mechanical failure - MAP sensor - Connector terminals Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing Manifold Pressure/Vacuum Sensor: Testing and Inspection Component Testing Fig. 82 MAP Sensor Connector CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 1 and 4 (Fig. 82). With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. If OK, go to next step. - If not OK, go to step 3. 2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness condition. Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 43. - If OK, go to next step. - If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 3 and 1 with the key ON. The voltage should be approximately 5 volts ± 0.5V). Five volts (± 0.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor. - If not OK, repair or replace the wire harness as required. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing > Page 2778 Manifold Pressure/Vacuum Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Component Testing > Page 2779 Manifold Pressure/Vacuum Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 2780 Manifold Pressure/Vacuum Sensor: Service and Repair Map/Intake Air Temperature Sensor Fig. 98 MAP/IAT Sensor-DOHC NOTE: The MAP/IAT sensor attaches to the intake manifold plenum (Fig. 98). Fig. 97 Air Inlet Duct-DOHC REMOVAL 1. Remove air inlet duct wing nut and duct from intake manifold (Fig. 97). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 2781 2. Disconnect the electrical connector from the MAP/IAT sensor. 3. Remove sensor mounting screws. 4. Remove sensor. INSTALLATION 1. Insert sensor into intake manifold while making sure not to damage 0-ring seals. 2. Tighten mounting screws to 2 Nm (20 in lb) torque for a plastic manifold and 3 Nm (30 in lb) for a aluminum manifold. 3. Attach electrical connector to sensor 4. Install air inlet duct wing nut and duct from intake manifold, insure that the duct does not interfer with ignition cables. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Upstream and Downstream Heated Oxygen Sensors Torque = 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2787 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2788 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2789 Downstream Oxygen Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2790 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor Oxygen Sensor: Description and Operation Heated Oxygen Sensor CIRCUIT OPERATION Circuit A14 is a bus bar in the Power Distribution Center (PDC), and connects to battery voltage. The contact side of the Automatic Shut Down (ASD) relay connects circuit A14 and circuit A142. A 20 Amp fuse in the PDC protects circuits A14 and A142. Circuit A14 also supplies voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) controls the ground path circuit for the coil side of the ASD relay on circuit K51. Circuit K51 connects to cavity 67 of the PCM connector. Circuit A142 splices to supply voltage for the upstream and downstream heated oxygen sensors. The A142 circuit also splices to cavity 6 of the PCM. The input provided by circuit A142 at cavity 6 tells the PCM that the ASD relay energized. Circuit K41 delivers the signal from the upstream heated oxygen sensor to the PCM. Circuit K41 connects to cavity 30 of the PCM connector. Circuit K141 delivers the signal from the down-stream heated oxygen sensor to the PCM. Circuit K141 connects to cavity 51 of the PCM connector. The PCM provides a ground for the upstream and downstream heated oxygen sensor signals (circuit K41 and K141) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector Circuit Z1 provides ground for the heater circuits in each sensor. Circuit Z1 terminates at the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor > Page 2793 Oxygen Sensor: Description and Operation Related Trouble Codes & Set Conditions Downstream O2 Sensor Heater Failure Name of Code: Downstream O2 Sensor Heater Failure When Monitored: With the ignition key oft, after the engine cools down Set Condition: No sensor output signal is received when the PCM powers up the sensor heater. Theory of Operation: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this 02 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases the downstream oxygen sensor tells the PCM how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. This O2 sensor serves as an indicator of oxygen content. The heater element helps the O2 sensor quickly reach a normal and steady operating temperature, which is required for proper emission control. Possible Causes: - Open heater element circuit - O2 sensor failure - Powertrain control module failure - Connector terminals - Connector wires Downstream O2 Sensor Shorted to Ground Name of Code: Downstream O2S Voltage Shorted To Ground When Monitored: With the ignition key off, after the engine cools down. Set Condition: The downstream oxygen sensor signal voltage is below 0.156 volt prior to O2 sensor heater test. Theory of Operation: The downstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the downstream oxygen sensor tells the PCM how well the catalytic converter is oxidizing HC and CO components and reducing NOx components in the engine exhaust gas. Variations in the signal from the O2 sensor serve as an indicator of oxygen content. The catalytic converter absorbs the oxygen in the exhaust gas when the fuel/air mixture is lean. The downstream 02 sensor indicates a deficiency of oxygen when the upstream 02 sensor detects an abundance of oxygen and vice versa. Possible Causes: - Sensor output wire shorted to another circuit - Dirty connection causing voltage tracking in connector - O2 sensor failure - Powertrain control module failure - Connector terminals/wires Downstream O2 Sensor Shorted to Voltage Name of Code: Downstream O2 Sensor Shorted To Voltage When Monitored: With the ignition key on. Set Condition: The engine running for more than 2 minutes and coolant temp. above 176°F. The upstream oxygen sensor signal voltage is above 1.2 volts for 2.6 seconds. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor > Page 2794 Theory of Operation: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. Possible Causes: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure - Powertrain control module failure - Connector terminals - Connector wires Downstream O2 Sensor Stays at Center Name of Code: Downstream O2 Sensor Stays At Center When Monitored: With the vehicle engine running for more than two minutes, engine temperature greater than 170°F, in closed loop. Set Condition: If oxygen sensor voltage stays between 0.29 volts and 0.72 volts for 30 seconds, the PCM pulls the sensor voltage to 5.0 volts for 60 seconds and monitors the sensor voltage. If the voltage stays at 5.0 volts, this trouble code will set, indicating no activities. Theory of Operation: Effective control of exhaust emissions is achieved by an oxygen feedback system. The downstream oxygen sensor (O2S), located in the exhaust path, monitors the exhaust emissions. Once the sensor reaches its normal operating temperature of 300°-350° C (572°-662° F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the efficiency of the catalytic converter. The downstream oxygen sensor is monitored for proper response to assure a correct catalytic converter efficiency calculation. A good sensor will indicate a rich condition when at WOT (due to the enriched F/A ratio), and a lean condition when in decel fuel shut-off (due to the lean F/A ratio). Possible Causes: - Sensor output wire open - Dirt/moisture/grease inside connector - Open ground circuit - Oxygen sensor failure - PCM failure Slow Upstream O2 Sensor During Catalyst Monitor Name of Code: Slow Upstream O2 Sensor During Catalyst Monitor When Monitored: With the engine running, coolant greater than 17O°F, open throttle, steady to slightly increasing vehicle speed between 18 MPH and 55 MPH, with a light load on the engine, for a period no less than five minutes. Set Condition: The upstream oxygen sensor signal voltage is switching from below 0.39 volt to above 0.6 volt and back fewer times than required. Theory of Operation: Effective control of exhaust emissions is achieved by an oxygen feedback system, of which the most important element is the upstream oxygen sensor (O2S). which is located in the exhaust path. Once the sensor reaches its normal operating temperature of 30O° to 350°C (572° to 662°F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the fuel injector pulse width, which maintains the optimum 14.7 to 1 air/fuel (A/F) ratio that is required for the catalytic converter to best control exhaust emissions. Response rate is the time required for the sensor to detect changes in the exhaust gas oxygen content; it switches from lean to rich if it is exposed to a richer than optimum A/F mixture, or vice versa. The O2S output voltage ranges from 0 to 1 volt. A good sensor easily generates an output voltage in this range as it is exposed to different oxygen concentrations. To detect a shift in the A/F mixture (lean or rich), the output voltage has to change beyond a threshold value. A malfunctioning sensor could have difficulty changing beyond the thresholds. Possible Causes: - Exhaust leak Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor > Page 2795 - Dirt/moisture/grease inside connector - Fuel contamination - Engine mechanical - Weak upstream O2 sensor with deteriorated catalyst Upstream O2 Sensor Heater Failure Name of Code: Upstream O2 Sensor Heater Failure When Monitored: With the Ignition key off, after the engine cools down. Set Condition: No sensor output signal is received when the PCM powers up the sensor heater. Theory of Operation: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases. the upstream oxygen sensor tells the PCM how well its output signal is controlling the air/fuel ratio. Variations in the signals from the O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/ fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. The heater element helps the 02 sensor quickly reach a normal and steady operating temperature. which is required for proper emission control. Possible Causes: - Open heater element circuit - 02 sensor failure - PCM failure - Dirt/moisture/grease inside connector - 02 sensor heater wires - ASD relay failure Upstream O2 Sensor Shorted to Voltage Name of Code: Upstream 02 Sensor Shorted to Voltage When Monitored: With the ignition key on. Set Condition: The engine running for more than 2 minutes and coolant temperature above 176°F. The upstream oxygen sensor signal voltage is above 1.2 volts for 2.6 seconds. Theory of Operation: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. Possible Causes: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - 02 sensor failure - Powertrain control module failure - Connector terminals - Connector wires Upstream O2 Sensor Slow Response Name of Code: Upstream O2 Sensor Slow Response When Monitored: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor > Page 2796 With the engine running for more than 3 minutes, engine temperature greater than 120°F, after reaching a vehicle speed of 20 mph for 120 seconds, at idle with the transmission in drive (auto) or in neutral (manual). Set Condition: The upstream oxygen sensor signal voltage is switching from below 0.39 volt to above 0.6 volt and back fewer times than required. Theory of Operation: Effective control of exhaust emissions is achieved by an oxygen feedback system, of which the most important element is the upstream oxygen sensor (O2S), which is located in the exhaust path. Once the sensor reaches its normal operating temperature of 300°C-350°C (572°F - 662°F), it generates a voltage inversely proportional to the amount of oxygen in the exhaust. This voltage is used to calculate the fuel injector pulse width, which maintains the optimum 14.7 to 1 air/fuel (A/F) ratio that is required for the catalytic converter to best control exhaust emissions. Response rate is the time required for the sensor to detect changes in the exhaust gas oxygen content; it switches from lean to rich if it is exposed to a richer than optimum A/F mixture, or vice versa. The O2S output voltage ranges from 0 to 1 volt. A good sensor easily generates an output voltage in this range as it is exposed to different oxygen concentrations. To detect a shift in the A/F mixture (lean or rich), the output voltage has to change beyond a threshold value. A malfunctioning sensor could have difficulty changing beyond the thresholds. Possible Causes: - Exhaust leak - Dirt/moisture/grease inside connector - Fuel contamination - Engine mechanical Upstream O2 Sensor Stays at Center Name of Code: Upstream O2 Sensor Stays at Center When Monitored: With the engine running for more than 2 minutes and engine temperature greater than 17O°F. Set Condition: The upstream oxygen sensor signal voltage is between 0.35 volts and 0.55 volts for 1.5 minutes. Theory of Operation: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from this O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this 02 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. Possible Causes: - Sensor output wire open - O2 sensor failure - PCM failure - Dirt/moisture/grease causing voltage tracking in connector - Connector wires Upstream O2S Voltage Shorted to Ground Name of Code: Upstream 02S Voltage Shorted To Ground When Monitored: With engine coolant temperature above 170°F on the previous key on, after a cold start, engine coolant below 98°F, and ambient/ battery sensor reading within 27°F of engine coolant. Set Condition: The upstream oxygen sensor signal voltage is below 0.156 volts for 28 seconds after starting engine. Theory of Operation: The upstream oxygen sensor is a voltage generating device. The PCM receives exhaust gas information from the O2 sensor. The sensor detects exhaust gas content by a galvanic reaction within the sensor that produces a voltage. After measuring the amount of oxygen in the exhaust gases, the upstream oxygen sensor tells the PCM how well its output signals are controlling the air/fuel ratio. Variations in the signal from this O2 sensor serve as air/fuel ratio indicators. Changes in the sensor signal occur because the air/fuel ratio is constantly changing. When oxygen content is low (rich mixture), the voltage signal will be low, approximately 0.1 volt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor > Page 2797 Possible Causes: - Sensor output wire shorted to another circuit - Dirty/wet connection causing voltage tracking in connector - O2 sensor failure - Powertrain control module failure - Connector terminals - Connector wires to sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, ASD relay, generator, and the upstream and downstream heated oxygen sensors. The PCM controls the ground circuit for each of the components powered by circuit A142. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2800 Oxygen Sensor: Testing and Inspection Oxygen Sensor Heater Circuit Test NOTE: Use an ohmmeter to test the heating element of the oxygen sensors. 1. Disconnect the electrical connector from each oxygen sensor. - The white wires in the sensor connector are the power and ground circuits for the heater elements. 2. Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. - Replace the heated oxygen sensor if the resistance is not between 4 and 7 ohms. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor Oxygen Sensor: Service and Repair Downstream O2 Sensor Fig. 19 Downstream Heated Oxygen Sensor NOTE: The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic convertor (Fig. 19). REMOVAL 1. Raise vehicle. 2. Disconnect electrical connector from sensor. 3. Disconnect sensor electrical harness from clips along body. Fig. 20 Downstream Heated Oxygen Sensor Removal/Installation 4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 20). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 2803 Oxygen Sensor: Service and Repair Upstream O2 Sensor Fig. 18 Upstream Heated Oxygen Sensor Removal/Installation REMOVAL 1. Raise and support vehicle. 2. Unplug sensor connector. 3. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or equivalent (Fig. 18). INSTALLATION 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. 2. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite® 771-64 or equivalent. - New sensors have compound on the threads and do not require an additional coating. 3. Tighten the sensor to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 2804 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 2809 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2810 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2811 Power Steering Pressure Switch: Description and Operation Fig. 15 Power Steering Pressure Switch PURPOSE On vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. The pressure switch improves vehicle idle quality, by controlling engine idle speed when required. The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed is increased. This increase in engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The power steering pressure switch is mounted directly to the power steering gear on vehicles requiring its usage. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z12 provides ground for the power steering pressure switch. The grounding point for circuit Z12 is the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 2812 Power Steering Pressure Switch: Testing and Inspection Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: Customer Interest Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 2821 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: All Technical Service Bulletins Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 2827 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2830 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2831 Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2832 Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS mounts to the throttle body and connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- from 0.38 to 1.03 volts. - AT Wide open throttle -- 3.1 to 4.0 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). CIRCUIT OPERATION From the Powertrain Control Module (PCM) circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 2835 Throttle Position Sensor: Description and Operation Related Trouble Codes & Set Conditions Throttle Position Sensor Voltage High Name of Code: Throttle Position Sensor Voltage High When Monitored: With the ignition on. Set Condition: TP sensor voltage at PCM cavity 35 goes above 4.5 volts for 0.704 seconds. Theory of Operation: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 35. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. Possible Causes: - Sensor signal circuit open - Throttle position sensor failure - Sensor ground circuit open - PCM failure - Connector terminals - Connector wires Throttle Position Sensor Voltage Low NAME OF CODE: Throttle Position Sensor Voltage Low WHEN MONITORED: With the ignition ON. SET CONDITION: The Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 35 goes below 0.2 volt for 0.704 seconds, or MPH is above 20, RPM is above 1500, and vacuum is below 2" with TP sensor voltage less than 0.5 volt for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Throttle position sensor failure - Loss of 5-volt supply TPS Voltage Does Not Agree With MAP Name of Code: TPS Voltage Does Not Agree with MAP When Monitored: With the engine running and no MAP sensor or TP sensor trouble codes. Set Condition: The powertrain control module (PCM) performs two separate tests on the TP sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 mph and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 4 continuous seconds. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 2836 Theory of Operation: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from the PCM. The sensor ground is provided by the PCM. Possible Causes: - Failed powertrain control module - Connector wires - TP sensor failure - Vehicle speed - Mechanical failure - MAP sensor - Connector terminals Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2839 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor around terminal. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately 0.38 volts to 1.03 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.0 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2840 Throttle Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2841 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2842 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (20 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Throttle Position Sensor Mounting Screws 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2846 Transmission Connections Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2849 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2850 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2851 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2852 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2853 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2854 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2855 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2856 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2857 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2858 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2859 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2860 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2861 Transmission Position Switch/Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2862 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2863 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2864 Rear Lighting (Part 1 Of 3) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Park/Neutral Position Switch Operation Transmission Position Switch/Sensor: Description and Operation Park/Neutral Position Switch Operation Fig. 20 Park/Neutral Switch OPERATION The park/neutral position switch is located on the automatic transaxle housing Fig. 20. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. CIRCUIT OPERATION When CLOSED the Transmission Range Switch (TRS) provides an input to the Powertrain Control Module (PCM) on circuit T41. This circuit connects to cavity 76 of the PCM connector. The T41 circuit is spliced and provides a ground path for the engine starter relay, and the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Park/Neutral Position Switch Operation > Page 2867 Transmission Position Switch/Sensor: Description and Operation Park/Neutral Switch Failure Trouble Code Name of Code: Park/Neutral Switch Failure (Sense Circuit) When Monitored: With the transmission in Park, Neutral, or Drive and not in limp-in mode. Set Condition: This code is set if the PCM detects an incorrect Park/Neutral switch state for a given mode of vehicle operation. Theory of Operation: The Transmission range Sensor (Park/Neutral position switch on 3 speed auto and all manual trans) is used to communicate whether or not the transmission is in Park or Neutral to the PCM. When the transmission is in Park or Neutral the Park/Neutral position switch sense circuit is grounded. Possible Causes: - Connector terminals and/or wires - Park/Neutral switch failure - Mechanical transmission problem - PCM failure Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 2868 Transmission Position Switch/Sensor: Testing and Inspection Park/Neutral Starting and Back-Up Lamp Switch 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 the switch, remove the wiring connector from the switch and test for continuity between the center pin of the switch and the transaxle case. Continuity should exist only when the transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 1. To test the switch, remove the wiring connector from the switch and test for continuity between the two outside pins. Continuity should only exist with the transaxle in the REVERSE position. 2. No continuity should exist from either pin to the transaxle case. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 2869 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Starting and Back-Up Lamp Switch Removal 1. Place a suitable container under the switch to catch fluid when switch is removed. 2. Unscrew switch from transaxle case allowing fluid to drain into container. 3. Move selector lever to PARK, then NEUTRAL position and inspect to see the switch operating lever fingers are centered in the switch opening. Installation 1. Crew the switch with a new seal into the transaxle case and tighten to 33 Nm (24 ft. lbs.). 2. Test switch with a test lamp. 3. Add fluid to transaxle to bring up to proper level. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Mounting Bolt 2.2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2873 Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2876 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2877 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2878 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2879 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2880 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2881 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2882 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2883 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2884 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2885 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2886 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2887 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2888 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2889 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2890 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 2891 Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > No Vehicle Speed Sensor Signal Trouble Code Vehicle Speed Sensor: Description and Operation No Vehicle Speed Sensor Signal Trouble Code With Electronic Automatic Transaxle NAME OF CODE: No Vehicle Speed Sensor Signal WHEN MONITORED: With engine running more than 31 seconds, engine temperature greater than 120°F, transmission not in park or neutral, brakes not applied, engine RPM greater than 1800, and MAP vacuum less than 11". SET CONDITION: No signal from the vehicle speed sensor (VSS) for more than 11 seconds. THEORY OF OPERATION: The vehicle speed sensor signal is provided to the PCM by the TCM. The signal is calculated by the TCM based on the output speed sensor signal and the speedometer pinion factor. The PCM supplies a 5 volt pull up voltage from cavity 66 to TCM cavity 58. The sensor signal is created by the TCM alternating the signal from 5V to 0.3V. POSSIBLE CAUSES: - Open or shorted signal circuit - Speedometer pinion factor not programmed - Open vehicle speed sensor circuit - PCM failure - TCM failure Without Electronic Automatic Transaxle Name of Code: No Vehicle Speed Sensor Signal When Monitored: With engine running more than 31 seconds, engine temperature greater than 180°F, transmission not in park or neutral, brakes not applied, engine rpm greater than 1,800, and MAP vacuum less than 11". Set Condition: No signal from the vehicle speed sensor for more than 11 seconds. Theory of Operation: The vehicle speed sensor is a hall-effect type sensor used to detect the transmission output shaft speed. The PCM calculates the vehicle speed based on the VSS signal. The PCM supplies 8 volts to power up the sensor. Sensor ground is supplied by the PCM. The PCM also supplies a 5.0 volt pull up voltage to the sensor. The VSS signal is created when the sensor alternates the 5.0 volt pull up from high to low. Possible Causes: - Open or shorted signal circuit - Speedometer pinion damaged - Open 5-volt supply circuit - Open sensor ground circuit - Failed vehicle speed sensor - PCM failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > No Vehicle Speed Sensor Signal Trouble Code > Page 2894 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor-PCM Input Fig. 17 Vehicle Speed Sensor -- Automatic Transmission Fig. 18 Vehicle Speed Sensor -- Manual Transmission PURPOSE The sensor input is used by the PCM to determine vehicle speed and distance traveled. OPERATION The vehicle speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. Under deceleration conditions, the PCM adjusts the Idle Air Control (IAC) motor to maintain a desired MAP value. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. The vehicle speed sensor signal is also used to operate: Speedometer - Speed control - Daytime Running Lights (Canadian Vehicles only). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the Vehicle Speed Sensor (VSS). The K7 circuit connects to cavity 44 of the PCM connector. Circuit G7 from the VSS provides an input signal to the PCM. The G7 circuit connects to cavity 66 of the PCM connector. The PCM provides ground for the VSS signal (circuit G7) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Helpful Information Vehicle Speed Sensor: Testing and Inspection Helpful Information Circuit G7 splices to the speedometer and odometer in the instrument cluster. Circuit K7 splices to supply 8 Volts to the camshaft position sensor and crankshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2897 Vehicle Speed Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 2898 Vehicle Speed Sensor: Service and Repair Fig. 24 Vehicle Speed Sensor Fig. 7 Vehicle Speed Sensor And Connector Fig. 8 Vehicle Speed Sensor And Speedometer Pinion Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 2899 NOTE: The vehicle speed sensor is located in the transmission extension housing (Fig. 24). REMOVAL 1. Disconnect electrical connector from sensor. 2. Remove the sensor mounting bolt. 3. Lift the sensor out of the transaxle extension housing. Ensure the 0-ring was removed with the sensor. NOTE: The speed sensor gear meshes with a gear on the output shaft. INSTALLATION 1. With 0-ring in place, install sensor and seat sensor by hand -- to ensure proper gear engagement. 2. Install mounting bolt and torque bolt to 2.2 Nm (20 in lb). 3. Connect electrical connector to sensor. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: Customer Interest Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 2908 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: All Technical Service Bulletins Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 2914 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2917 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2918 Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2919 Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS mounts to the throttle body and connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- from 0.38 to 1.03 volts. - AT Wide open throttle -- 3.1 to 4.0 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). CIRCUIT OPERATION From the Powertrain Control Module (PCM) circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 2922 Throttle Position Sensor: Description and Operation Related Trouble Codes & Set Conditions Throttle Position Sensor Voltage High Name of Code: Throttle Position Sensor Voltage High When Monitored: With the ignition on. Set Condition: TP sensor voltage at PCM cavity 35 goes above 4.5 volts for 0.704 seconds. Theory of Operation: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 35. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. Possible Causes: - Sensor signal circuit open - Throttle position sensor failure - Sensor ground circuit open - PCM failure - Connector terminals - Connector wires Throttle Position Sensor Voltage Low NAME OF CODE: Throttle Position Sensor Voltage Low WHEN MONITORED: With the ignition ON. SET CONDITION: The Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 35 goes below 0.2 volt for 0.704 seconds, or MPH is above 20, RPM is above 1500, and vacuum is below 2" with TP sensor voltage less than 0.5 volt for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Throttle position sensor failure - Loss of 5-volt supply TPS Voltage Does Not Agree With MAP Name of Code: TPS Voltage Does Not Agree with MAP When Monitored: With the engine running and no MAP sensor or TP sensor trouble codes. Set Condition: The powertrain control module (PCM) performs two separate tests on the TP sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 mph and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 4 continuous seconds. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 2923 Theory of Operation: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from the PCM. The sensor ground is provided by the PCM. Possible Causes: - Failed powertrain control module - Connector wires - TP sensor failure - Vehicle speed - Mechanical failure - MAP sensor - Connector terminals Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2926 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor around terminal. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately 0.38 volts to 1.03 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.0 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2927 Throttle Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2928 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2929 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (20 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Torque Reduction Signal > Component Information > Description and Operation Torque Reduction Signal: Description and Operation TORQUE MANAGEMENT INPUT Circuit T10 connects from the Transmission Control Module (TCM) to the Powertrain Control Module (PCM) cavity 63. This is the torque management request from the TCM to the PCM. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Throttle Position Sensor Mounting Screws 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2936 Transmission Connections Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2939 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2940 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2941 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2942 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2943 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2944 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2945 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2946 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2947 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2948 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2949 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2950 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2951 Transmission Position Switch/Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2952 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2953 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2954 Rear Lighting (Part 1 Of 3) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Park/Neutral Position Switch Operation Transmission Position Switch/Sensor: Description and Operation Park/Neutral Position Switch Operation Fig. 20 Park/Neutral Switch OPERATION The park/neutral position switch is located on the automatic transaxle housing Fig. 20. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. CIRCUIT OPERATION When CLOSED the Transmission Range Switch (TRS) provides an input to the Powertrain Control Module (PCM) on circuit T41. This circuit connects to cavity 76 of the PCM connector. The T41 circuit is spliced and provides a ground path for the engine starter relay, and the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Park/Neutral Position Switch Operation > Page 2957 Transmission Position Switch/Sensor: Description and Operation Park/Neutral Switch Failure Trouble Code Name of Code: Park/Neutral Switch Failure (Sense Circuit) When Monitored: With the transmission in Park, Neutral, or Drive and not in limp-in mode. Set Condition: This code is set if the PCM detects an incorrect Park/Neutral switch state for a given mode of vehicle operation. Theory of Operation: The Transmission range Sensor (Park/Neutral position switch on 3 speed auto and all manual trans) is used to communicate whether or not the transmission is in Park or Neutral to the PCM. When the transmission is in Park or Neutral the Park/Neutral position switch sense circuit is grounded. Possible Causes: - Connector terminals and/or wires - Park/Neutral switch failure - Mechanical transmission problem - PCM failure Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 2958 Transmission Position Switch/Sensor: Testing and Inspection Park/Neutral Starting and Back-Up Lamp Switch 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 the switch, remove the wiring connector from the switch and test for continuity between the center pin of the switch and the transaxle case. Continuity should exist only when the transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 1. To test the switch, remove the wiring connector from the switch and test for continuity between the two outside pins. Continuity should only exist with the transaxle in the REVERSE position. 2. No continuity should exist from either pin to the transaxle case. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 2959 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Starting and Back-Up Lamp Switch Removal 1. Place a suitable container under the switch to catch fluid when switch is removed. 2. Unscrew switch from transaxle case allowing fluid to drain into container. 3. Move selector lever to PARK, then NEUTRAL position and inspect to see the switch operating lever fingers are centered in the switch opening. Installation 1. Crew the switch with a new seal into the transaxle case and tighten to 33 Nm (24 ft. lbs.). 2. Test switch with a test lamp. 3. Add fluid to transaxle to bring up to proper level. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Mounting Bolt 2.2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2963 Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2966 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2967 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2968 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2969 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2970 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2971 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2972 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2973 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2974 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2975 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2976 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2977 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2978 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2979 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2980 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2981 Vehicle Speed Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > No Vehicle Speed Sensor Signal Trouble Code Vehicle Speed Sensor: Description and Operation No Vehicle Speed Sensor Signal Trouble Code With Electronic Automatic Transaxle NAME OF CODE: No Vehicle Speed Sensor Signal WHEN MONITORED: With engine running more than 31 seconds, engine temperature greater than 120°F, transmission not in park or neutral, brakes not applied, engine RPM greater than 1800, and MAP vacuum less than 11". SET CONDITION: No signal from the vehicle speed sensor (VSS) for more than 11 seconds. THEORY OF OPERATION: The vehicle speed sensor signal is provided to the PCM by the TCM. The signal is calculated by the TCM based on the output speed sensor signal and the speedometer pinion factor. The PCM supplies a 5 volt pull up voltage from cavity 66 to TCM cavity 58. The sensor signal is created by the TCM alternating the signal from 5V to 0.3V. POSSIBLE CAUSES: - Open or shorted signal circuit - Speedometer pinion factor not programmed - Open vehicle speed sensor circuit - PCM failure - TCM failure Without Electronic Automatic Transaxle Name of Code: No Vehicle Speed Sensor Signal When Monitored: With engine running more than 31 seconds, engine temperature greater than 180°F, transmission not in park or neutral, brakes not applied, engine rpm greater than 1,800, and MAP vacuum less than 11". Set Condition: No signal from the vehicle speed sensor for more than 11 seconds. Theory of Operation: The vehicle speed sensor is a hall-effect type sensor used to detect the transmission output shaft speed. The PCM calculates the vehicle speed based on the VSS signal. The PCM supplies 8 volts to power up the sensor. Sensor ground is supplied by the PCM. The PCM also supplies a 5.0 volt pull up voltage to the sensor. The VSS signal is created when the sensor alternates the 5.0 volt pull up from high to low. Possible Causes: - Open or shorted signal circuit - Speedometer pinion damaged - Open 5-volt supply circuit - Open sensor ground circuit - Failed vehicle speed sensor - PCM failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > No Vehicle Speed Sensor Signal Trouble Code > Page 2984 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor-PCM Input Fig. 17 Vehicle Speed Sensor -- Automatic Transmission Fig. 18 Vehicle Speed Sensor -- Manual Transmission PURPOSE The sensor input is used by the PCM to determine vehicle speed and distance traveled. OPERATION The vehicle speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. Under deceleration conditions, the PCM adjusts the Idle Air Control (IAC) motor to maintain a desired MAP value. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. The vehicle speed sensor signal is also used to operate: Speedometer - Speed control - Daytime Running Lights (Canadian Vehicles only). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the Vehicle Speed Sensor (VSS). The K7 circuit connects to cavity 44 of the PCM connector. Circuit G7 from the VSS provides an input signal to the PCM. The G7 circuit connects to cavity 66 of the PCM connector. The PCM provides ground for the VSS signal (circuit G7) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Helpful Information Vehicle Speed Sensor: Testing and Inspection Helpful Information Circuit G7 splices to the speedometer and odometer in the instrument cluster. Circuit K7 splices to supply 8 Volts to the camshaft position sensor and crankshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2987 Vehicle Speed Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 2988 Vehicle Speed Sensor: Service and Repair Fig. 24 Vehicle Speed Sensor Fig. 7 Vehicle Speed Sensor And Connector Fig. 8 Vehicle Speed Sensor And Speedometer Pinion Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 2989 NOTE: The vehicle speed sensor is located in the transmission extension housing (Fig. 24). REMOVAL 1. Disconnect electrical connector from sensor. 2. Remove the sensor mounting bolt. 3. Lift the sensor out of the transaxle extension housing. Ensure the 0-ring was removed with the sensor. NOTE: The speed sensor gear meshes with a gear on the output shaft. INSTALLATION 1. With 0-ring in place, install sensor and seat sensor by hand -- to ensure proper gear engagement. 2. Install mounting bolt and torque bolt to 2.2 Nm (20 in lb). 3. Connect electrical connector to sensor. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Specifications Voltage Signal: Specifications The PCM tries to maintain system voltage between 12.9 volts and 15.0 volts. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Specifications > Page 2993 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Description and Operation > Description of Operation Voltage Signal: Description and Operation Description of Operation THEORY OF OPERATION: The PCM monitors battery voltage input to determine fuel injector pulse width and generator field control voltage. Injector Pulse Width If voltage is low the PCM will increase pulse width (the period of time that the injector is energized). Generator Field Voltage The PCM tries to maintain a system voltage between 12.9 volts and 15.0 volts. The voltage determined by the PCM as the final goal for the charging system is called "control" voltage. This control voltage is determined from the battery temp sensor for ambient sensor and the sensed voltage system voltage at the PCM. The control voltage is compared to the sensed voltage continuously during running. If the sensed voltage is less than the control voltage the PCM will supply more ground to the field circuit. - If the sensed voltage is more than the control voltage the PCM will supply less ground to the field circuit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Description and Operation > Description of Operation > Page 2996 Voltage Signal: Description and Operation Related Trouble Codes and Set Conditions Charging System Voltage Too Low Name of Code: Charging System Voltage Too Low When Monitored: With the ignition key on and the engine running above 1,500 RPM. Set Condition: With no other charging system codes set. The battery sensed voltage is 1 volt below the charging goal for 25 seconds. The PCM senses the battery voltage, turns off the field driver and senses the battery voltage again. If the voltages are the same this code is set. Theory of Operation: The PCM tries to maintain a system voltage between 12.9 volts and 15.0 volts. The voltage determined by the PCM as the final goal for the charging system is called control voltage. This control voltage is determined from the battery temp sensor (ambient sensor). The control voltage is compared to the sensed voltage continuously during running. If the sensed voltage is less than the control voltage the PCM will supply more ground to the field circuit. If the sensed voltage is more than the control voltage the PCM will supply less ground to the field circuit. Possible Causes: - Defects in generator drive belt or adjustment - High resistance between battery B(+) and generator B(+) - High resistance between battery B(-) and generator B(-) - PCM failure - Connector terminals - Connector wires - High field circuit resistance (in generator) Generator Field Not Switching Properly Name of Code: Generator Field Not Switching Properly When Monitored: With the ignition key on and the engine running. Set Condition: When the PCM tries to regulate the generator field with no result during monitoring. Theory of Operation: The PCM tries to maintain a system voltage between 12.9 volts and 15.0 volts. The voltage determined by the PCM as the final goal for the charging system is called "control voltage". This control voltage is determined from the battery temp sensor (ambient sensor). The control voltage is compared to the sensed voltage continuously during running. If the sensed voltage is less than the control voltage, the PCM will supply more ground to the field circuit. If the sensed voltage is more than the control voltage, the PCM will supply less ground to the field circuit. Possible Causes: - Field driver circuit open or shorted - Generator internal open or short - PCM failed Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Description and Operation > Page 2997 Voltage Signal: Testing and Inspection Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Description and Operation Catalyst Shield: Description and Operation CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. PURPOSE The heat shield is needed to protect both the car and the environment from the high temperatures developed in the vicinity of the catalytic converter. CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shield on cars. Light over-spray near the edges is permitted. Application of coating will greatly reduce the efficiency of the heat shields resulting in excessive floor pan temperatures and objectionable fumes. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications Canister Purge Solenoid: Specifications Solenoid Coil Resistance @ 20°C (68°F) ......................................................................................................................................................... 25 - 35 ohms Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 3007 Canister Purge Solenoid: Locations Fig. 101 Upstream Heated Oxygen Sensor Removal/Installation & EVAP Purge Solenoid Location EVAP Purge Solenoid Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 3008 EVAP Purge Solenoid Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Description and Operation > Duty Cycle EVAP/Purge Solenoid Canister Purge Solenoid: Description and Operation Duty Cycle EVAP/Purge Solenoid Fig. 101 Upstream Heated Oxygen Sensor Removal/Installation & EVAP Purge Solenoid Location PURPOSE The duty cycle EVAP purge solenoid regulates the rate of vapor flow from the EVAP canister to the throttle body. The PCM operates the solenoid. OPERATION During the cold start warm-up period and the hot start time delay, the PCM does not energize the solenoid. When de-energized, no vapors are purged. When purging, the PCM energizes and de-energizes the solenoid approximately 5 or 10 times per second, depending upon operating conditions. The PCM varies the vapor flow rate by changing solenoid pulse width. - Pulse width is the amount of time the solenoid energizes. The solenoid attaches to a bracket which is attached to the front engine mount (Fig. 101). CIRCUIT OPERATION Circuit F12 supplies battery voltage to the Duty Cycle EVAP/Purge solenoid. The Powertrain Control Module (PCM) switches ground path for the solenoid ON and OFF through circuit K52. Circuit F12 connects to a bus bar in the fuse block fed by circuit A21. A 15 Amp fuse in the fuse block, cavity 10, protects circuit F12. Circuit F12 also connects to cavity 20 of the PCM connector. Circuit K52 connects to cavity 68 of the PCM, and cavity 1 of the solenoid connector. NOTE: The solenoid will not operate properly unless it is installed with the electrical connector at the top. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Description and Operation > Duty Cycle EVAP/Purge Solenoid > Page 3011 Canister Purge Solenoid: Description and Operation EVAP Purge Solenoid Circuit Failure Code NAME OF CODE: Evaporative Purge Solenoid Circuit WHEN MONITORED: With the ignition key ON and the engine running. SET CONDITION: After the arming conditions are satisfied: not powering down, not already in limp-in, time since the last solenoid activation>72 micro seconds. The PCM will set a trouble code if the actual state of the solenoid does not match the intended state. THEORY OF OPERATION: The EVAP purge solenoid is mounted on the right side shock tower. Its purpose is to regulate, by means of a duty cycle, the flow of vapors from the EVAP canister to the throttle body. The PCM controls the time the solenoid is ON during a duty cycle. During off idle operations (higher flows), higher percentages of duty cycle are used. At idle (lower flow), lower percentages of duty cycle are used. POSSIBLE CAUSES: - Open or shorted control circuit - Open fused ignition switch output circuit - Open or shorted solenoid control coil - PCM failure - Connector wires or terminals Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Canister Purge Solenoid: Initial Inspection and Diagnostic Overview EVAP Purge Solenoid Inspection EVAPORATIVE EMISSION PURGE SOLENOID INSPECTION NOTE: When disconnecting the vacuum hose, place an identification mark on it for proper re-connection. 1. Disconnect the vacuum hose from the solenoid valve. 2. Disconnect the harness connector. 3. Connect a hand vacuum pump to nipple (A) of the solenoid valve. 4. Check airtightness by applying a vacuum with voltage applied directly from the battery to the purge control solenoid valve. Battery Voltage / Normal Condition. Applied ....................................................................................... .......................................................................................................... Vacuum Leaks Not Applied ...... .............................................................................................................................................................. ............. Vacuum Maintained 5. Measure the resistance between the terminals of the solenoid valve. - Standard value: 25-35 ohms [at 20°C (68°F)] Helpful Information Circuit F12 splices to feed the Antilock Brake System (ABS) control module, PCM, Electronic EGR Transducer (EET) solenoid, leak detection pump, and the Torque Converter Clutch (TCC) solenoid. The F12 circuit also connects to a bus bar in the Power Distribution Center (PDC) that supplies voltage to the coil side of radiator fan relays, A/C clutch relay, and fuel pump relay. In the START or RUN position, the ignition switch connects circuit A1 from the fuse block and circuit A21. Circuit A1 connects to battery voltage and is protected by a 30 Amp fuse in the PDC. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3014 Canister Purge Solenoid: Component Tests and General Diagnostics Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Testing and Inspection > Page 3015 Canister Purge Solenoid: Service and Repair Fig. 101 Upstream Heated Oxygen Sensor Removal/Installation & EVAP Purge Solenoid Location NOTE: The solenoid attaches to a bracket near the front engine mount. The solenoid will not operate unless it is installed correctly REMOVAL 1. Disconnect electrical connector from solenoid. 2. Disconnect vacuum tubes from solenoid. 3. Remove solenoid from bracket. NOTE: The top of the solenoid has TOP printed on it. The solenoid will not operate unless it is installed correctly. INSTALLATION 1. Install solenoid on bracket. 2. Connect vacuum tube to solenoid. 3. Connect electrical connector to solenoid. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Description and Operation Evaporative Check Valve: Description and Operation PRESSURE RELIEF/ROLLOVER VALVE All vehicles have a combination pressure relief and rollover valve. The dual function valve relieves fuel tank pressure. The valve also prevents fuel flow through the fuel tank vent valve hoses should the vehicle rollover. All vehicles pass a 360 rollover. The pressure relief valve opens at a certain pressure. When fuel tank pressure increases above the calibrated pressure, the valve opens to release fuel tank vapors pressure. The charcoal filled evaporative canister stores the vapors. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Fig.1 EVAP Canister Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3022 Evaporative Emission Control Canister: Description and Operation Fig. 2 EVAP Canister All vehicles use a sealed, maintenance free, evaporative (EVAP) canister. Fuel tank pressure vents into the canister. The canister temporarily holds the fuel vapors until intake manifold vacuum draws them into the combustion chamber. The PCM purges the canister through the duty cycle EVAP purge solenoid. - The PCM purges the canister at predetermined intervals and engine conditions. The canister mounts to a bracket behind the front fascia on the passengers side of the vehicle (Fig. 2). The vacuum and vapor tube connect to the top of the canister. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Vacuum Pump Leak Detection Pump Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Vacuum Pump > Page 3027 EVAP System Service Port Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 3028 Leak Detection Pump Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Vapor Canister Leak Detector Leak Detection Pump: Description and Operation Vapor Canister Leak Detector Fig 4 Evaporative System Monitor PURPOSE The leak detection pump is a device used to detect a leak in the evaporative system. OPERATION The pump contains a 3 port solenoid, a pump that contains a switch, a spring loaded canister vent valve seal, 2 check valves and a spring diaphragm. Immediately after a cold start, engine temperature between 40°F and 86°F, the 3 port solenoid is briefly energized. This initializes the pump by drawing air into the pump cavity and also closes the vent seal. During non-test test conditions, the vent seal is held open by the pump diaphragm assembly which pushes it open at the fill travel position. The vent seal will remain closed while the pump is cycling. This is due to the operation of the 3 port solenoid which prevents the diaphragm assembly from reaching full travel. After the brief initialization period, the solenoid is de-energized, allowing atmospheric pressure to enter the pump cavity. This permits the spring to drive the diaphragm which forces air out of the pump cavity and into the vent system. When the solenoid is energized and de-energized, the cycle is repeated creating flow in typical diaphragm pump fashion. The pump is controlled in 2 modes: PUMP MODE: The pump is cycled at a fixed rate to achieve a rapid pressure build in order to shorten the overall test time. TEST MODE: The solenoid is energized with a fixed duration pulse. Subsequent fixed pulses occur when the diaphragm reaches the switch closure point. Leak Test The spring in the pump is set so that the system will achieve an equalized pressure of about 7.5 inches of water. When the pump starts, the cycle rate is quite high. As the system becomes pressurized pump rate drops. If there is no leak the pump will quit. - If there is a leak, the test is terminated at the end of the test mode. Purge Monitor If there is no leak, the purge monitor is run. If the cycle rate increases due to the flow through the purge system, the test is passed and the diagnostic is complete. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Vapor Canister Leak Detector > Page 3031 The canister vent valve will unseal the system after completion of the test sequence as the pump diaphragm assembly moves to the full travel position. CIRCUIT OPERATION Power for the vapor canister leak detector is provided on circuit F12. This circuit is protected by a 15 Amp fuse located in cavity 10 of the fuse block. Power for the fuse is supplied on circuit A21 from the ignition switch. Circuit A21 is HOT in the START and RUN position only. The Powertrain Control Module (PCM) controls the ground path for the leak detection pump solenoid and leak detection pump switch. Circuit K106 is connected to cavity 77 of the PCM connector and to the leak detection solenoid. Circuit K107 is connected to cavity 72 of the PCM connector and to the leak detection pump switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Vapor Canister Leak Detector > Page 3032 Leak Detection Pump: Description and Operation Related Trouble Codes and Set Conditions Leak Detection Pump Pressure Switch Name of Code: Leak Detection Pump Pressure Switch When Monitored: Immediately after a cold start, with ambient temperature between 40°F and 90°F and coolant temperature within 1O°F of ambient temperature Set Condition: The state of the switch does not change when the solenoid is energized. Theory of Operation: The leak detection assembly incorporates two primary functions: it detects a leak in the evaporative system and seals the evaporative system so the leak detection test can be run. The primary components within the assembly are a three-port leak detection solenoid that activates both of the functions described above, a pump containing a leak detection pump switch that monitors pump movement, two check valves and a spring diaphragm, and a canister vent valve seal containing a spring-loaded vent seal valve. When the solenoid is energized, it allows engine vacuum to enter the pump and draw the diaphragm up, thus allowing atmospheric pressure to enter the pump cavity. When the solenoid is deenergized, it vents the engine vacuum thus permitting the spring to drive the diaphragm down, forcing air out of the pump cavity into the vent system. When the solenoid is energized and deenergized, the cycle is repeated, which creates flow in a typical diaphragm pump fashion. After passing the leak detection phase of the test, system pressure is maintained until the purge system is activated, in effect creating a leak. If the cycle rate increases due to flow of the purge system, the test is passed and the diagnostic test is complete. If not, there is an obstruction in the system. Possible Causes: - Open or shorted LDP switch sense circuit - Leak detection pump switch failure - Open fused ignition switch output Leak Detection Pump Solenoid Circuit Name of Code: Leak Detection Pump Solenoid Circuit When Monitored: Immediately after a cold start, with ambient temperature between 40°F and 90°F and coolant temperature within 1O°F of ambient temperature Set Condition: The status of the solenoid does not change. Theory of Operation: The leak detection assembly incorporates two primary functions: it detects a leak in the evaporative system and seals the evaporative system so the leak detection test can be run. The primary components within the assembly are a three-port leak detection solenoid that activates both of the functions described above, a pump containing a leak detection pump switch that monitors pump movement, two check valves and a spring diaphragm, and a canister vent valve seal containing a spring-loaded vent seal valve. When the solenoid is energized, it allows engine vacuum to enter the pump and draw the diaphragm up, thus allowing atmospheric pressure to enter the pump cavity. When the solenoid is deenergized, it vents the engine vacuum thus permitting the spring to drive the diaphragm down, forcing air out of the pump cavity into the vent system. When the solenoid is energized and deenergized, the cycle is repeated, which creates flow in a typical diaphragm pump fashion. After passing the leak detection phase of the test, system pressure is maintained until the purge system is activated, in effect creating a leak. If the cycle rate increases due to flow of the purge system, the test is passed and the diagnostic test is complete. If not, there is an obstruction in the system. Possible Causes: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Vapor Canister Leak Detector > Page 3033 - Open or shorted LDP solenoid control circuit - Leak detection pump solenoid failure - Open fused ignition switch output Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Leak Detection Pump: Initial Inspection and Diagnostic Overview - Check the 15 Amp fuse located in cavity 10 of the fuse block. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3036 Leak Detection Pump: Component Tests and General Diagnostics Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Description and Operation EGR Backpressure Transducer: Description and Operation Fig. 1 EGR System Fig. 2 Electronic EGR Transducer (EET) The electronic EGR transducer (EET) contains an electrically operated solenoid and a back-pressure transducer (Fig. 2). The Powertrain Control Module (PCM) operates the solenoid. Exhaust system back-pressure controls the transducer. When exhaust system back-pressure becomes high enough, it fully closes a bleed valve in the transducer. - When the PCM de-energizes the solenoid and back-pressure closes the transducer bleed valve, vacuum flows through the transducer to operate the EGR valve. De-energizing the solenoid, but not fully closing the transducer bleed hole (because of low back-pressure), varies the strength of vacuum applied to the EGR valve. Varying the strength of the vacuum changes the amount of EGR supplied to the engine. This provides the correct amount of exhaust gas recirculation for different operating conditions. This system does not allow EGR at idle. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Description and Operation > Page 3041 EGR Backpressure Transducer: Service and Repair Fig. 1 EGR System NOTE: If the EGR system operates incorrectly, replace the entire EGR valve and transducer together. The EGR valve and Electronic EGR Transducer (EET) are calibrated together. NOTE: The EGR valve and EET attach to the rear of the cylinder head (Fig. 1). REMOVAL 1. Disconnect vacuum supply tube from EET solenoid. 2. Disconnect electrical connector from solenoid. 3. Remove EGR tube to EGR valve screws. 4. Remove EGR valve mounting screws. Remove EGR valve and transducer. 5. Clean gasket surfaces. Discard old gaskets. If necessary, clean EGR passages. INSTALLATION 1. Loosely install EGR valve with new gaskets. 2. Finger tighten EGR tube fasteners. 3. Tighten EGR tube fasteners to 11 Nm (95 in lb) torque. 4. Tightening EGR valve mounting screws to 22 Nm (200 in lb) torque. 5. Connect vacuum supply tube to solenoid. 6. Attach electrical connector to solenoid. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations EGR System Components Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 3045 EGR Solenoid Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Description and Operation > EGR Solenoid Circuit Trouble Code EGR Control Solenoid: Description and Operation EGR Solenoid Circuit Trouble Code Name of Code: EGR Solenoid Circuit When Monitored: With the ignition key on and engine running and battery voltage greater than 10 volts Set Condition: The EGR solenoid control circuit is not in the expected state when requested to operate by the PCM. Theory of Operation: The EGR solenoid is actuated by the PCM when the engine is at normal operating temperature. Throttle position sensor shows other than idle or WOT and MAP is in mid operating range. The PCM looks at current flow when actuating the solenoid. Possible Causes: - Open or shorted control circuit - Open fused ignition switch output circuit - Open or shorted solenoid control coil - Powertrain control module failure Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Description and Operation > EGR Solenoid Circuit Trouble Code > Page 3048 EGR Control Solenoid: Description and Operation Electronic Transducer (EET) Solenoid CIRCUIT OPERATION Circuit F12 supplies battery voltage to the Electronic EGR Transducer (EET) solenoid. The Powertrain Control Module (PCM) switches ground path for the solenoid ON and OFF through circuit K35. Circuit F12 connects to a bus bar in the fuse block fed by circuit A21. A 15 Amp fuse in the fuse block, cavity 10, protects circuit F12. Circuit F12 also connects to cavity 20 of the PCM. Circuit K35 connects to cavity 40 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview EGR Control Solenoid: Initial Inspection and Diagnostic Overview Circuit F12 splices to feed the ABS control module, PCM, Duty Cycle EVAP/Purge solenoid, leak detection pump, and the TCC solenoid. The F12 circuit also connects to a bus bar in the Power Distribution Center (PDC) that supplies voltage to the coil side of radiator fan relays, A/C clutch relay, and fuel pump relay. In the START or RUN position, the ignition switch connects circuit A1 from the fuse block and circuit A21. Circuit A1 connects to battery voltage and is protected by a 30 Amp fuse in the PDC. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3051 EGR Control Solenoid: Component Tests and General Diagnostics Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Testing and Inspection > Page 3052 EGR Control Solenoid: Service and Repair Fig. 1 EGR System NOTE: If the EGR system operates incorrectly, replace the entire EGR valve and transducer together. The EGR valve and Electronic EGR Transducer (EET) are calibrated together. NOTE: The EGR valve and EET attach to the rear of the cylinder head (Fig. 1). REMOVAL 1. Disconnect vacuum supply tube from EET solenoid. 2. Disconnect electrical connector from solenoid. 3. Remove EGR tube to EGR valve screws. 4. Remove EGR valve mounting screws. Remove EGR valve and transducer. 5. Clean gasket surfaces. Discard old gaskets. If necessary, clean EGR passages. INSTALLATION 1. Loosely install EGR valve with new gaskets. 2. Finger tighten EGR tube fasteners. 3. Tighten EGR tube fasteners to 11 Nm (95 in lb) torque. 4. Tightening EGR valve mounting screws to 22 Nm (200 in lb) torque. 5. Connect vacuum supply tube to solenoid. 6. Attach electrical connector to solenoid. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications EGR Tube: Specifications EGR tube to intake manifold ................................................................................................................ ....................................................... 11 Nm (95 in lb) EGR tube to EGR valve ....................................................................................................................... ....................................................... 11 Nm (95 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 3056 EGR Tube: Service and Repair Fig. 1 EGR System Fig. 3 EGR Tube Stud Bolts NOTE: The EGR tube attaches to the intake manifold plenum below the throttle body and EGR valve (Fig. 1). REMOVAL 1. Remove screws attaching EGR tube to intake manifold (Fig. 3). 2. Remove EGR tube to EGR valve screws. 3. Remove EGR tube. Clean gasket surface on the EGR valve. Wipe clean the grommet on the intake manifold. NOTE: The rubber grommet that seals the EGR tube to intake manifold connection is reusable. INSTALLATION 1. Loosely install the EGR tube and fasteners. 2. Tighten the EGR tube to intake manifold plenum screws to 11 Nm (95 in. lbs) torque. 3. Tighten the EGR tube to EGR valve screws to 11 Nm (95 in lb) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications EGR Valve: Specifications EGR valve to cyl. head ........................................................................................................................ ...................................................... 22 Nm (200 in lb) EGR tube to EGR valve ....................................................................................................................... ....................................................... 11 Nm (95 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3060 EGR Valve: Service and Repair Fig.3 EGR System NOTE: If the EGR system operates incorrectly, replace the entire EGR valve and transducer together. The EGR valve and electrical transducer (EET) are calibrated together. NOTE: The EGR valve attaches to the rear of the cylinder head (Fig. 3). EGR transducer is attached to the air inlet duct. REMOVAL 1. Remove EGR transducer from air inlet duct. 2. Disconnect vacuum supply tube from EGR transducer solenoid. 3. Disconnect electrical connector from solenoid. 4. Remove air inlet duct. 5. Remove EGR tube to EGR valve screws. 6. Remove EGR valve mounting screws. Remove EGR valve and transducer. 7. Clean gasket surfaces. Discard old gaskets. If necessary, clean EGR passages. INSTALLATION 1. Loosely install EGR valve with new gaskets. 2. Finger tighten EGR tube fasteners. 3. Tighten EGR tube fasteners to 11 Nm (95 in lb) torque. 4. Tightening EGR valve mounting screws to 22 Nm (200 in lb) torque. 5. Install air inlet duct. 6. Connect vacuum supply tube to solenoid. 7. Attach electrical connector to solenoid. 8. Install EGR transducer onto air inlet duct. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation Positive Crankcase Ventilation: Description and Operation Intake manifold vacuum removes crankcase vapors and piston blow-by from the separator. Emissions pass through the PCV valve into the intake manifold plenum. The vapors become part of the calibrated air-fuel mixture, are burned and then expelled with the exhaust gases. The air cleaner supplies make up air when the engine does not have enough vapor or blow-by gases. NOTE: In this system, fresh air does not enter the crankcase. PCV VALVE The PCV valve contains a spring loaded plunger. The plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum. Fig. 7 Engine Off Or Engine Backfire - No Vapor Flow When the engine is not operating or during an engine backfire, the spring forces the plunger back against the seat. This prevents vapors from flowing through the valve (Fig. 7). Fig. 8 High Intake Manifold Vacuum - Minimal Vapor Flow When the engine is at idle or cruising, high manifold vacuum is present. At these times manifold vacuum is able to completely compress the spring and pull the plunger to the top of the valve (Fig. 8). In this position there is minimal vapor flow through the valve. Fig. 9 Moderate Intake Manifold Vacuum - Maximum Vapor Flow During periods of moderate intake manifold vacuum the plunger is only pulled part way back from the inlet. This results in maximum vapor flow through the valve (Fig. 9). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Page 3064 Positive Crankcase Ventilation: Testing and Inspection Fig.9 PVC Test-Typical WARNING: Apply parking brake and/or block wheels before performing any test or adjustment with the engine operating. With the engine idling, remove the PCV valve from its attaching point. If the valve is operating properly, a hissing noise will be heard and a strong vacuum felt when placing a finger over the valve inlet (Fig. 9). With the engine off, shake the valve. The valve should rattle when shaken. Replace the valve if it does not operate properly. Do not attempt to clean the PCV valve. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Typical -- SOHC Shown Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 3073 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 12 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) 6. Replace Pressure test port cap when finished releasing pressure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Curb idle speed ................................................................................................................................... .......................................................... 700 +/- 100 rpm Idle speed when A/C is ON (in neutral) .......... .......................................................................................................................................................... 850 rpm Basic idle speed .................................................................................................................... .......................................................................... 700 +/- 50 rpm NOTE: If these specs differ from the under hood label, then use the information found on the under hood label. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3077 Idle Speed: Testing and Inspection Fig. 31 PCV Vacuum Nipple 1. Turn ignition key off. 2. Disconnect the PCV valve hose from the intake manifold nipple (Fig. 31). Cap the PCV vacuum nipple. Fig. 32 Purge Hose 3. Disconnect purge hose from the nipple on the throttle body (Fig. 32). Fig. 33 Orifice 6457 Attached To Purge Nipple 4. Use a piece of hose to attach Air Metering Orifice 6457 (0.125 in. orifice) or equivalent, to the purge nipple on the throttle body (Fig. 33). 5. Ensure that all accessories are off. 6. Connect the DRB or equivalent scan tool to the data link connector inside the passenger compartment. 7. Run engine in Park or Neutral until the cooling fan has cycled on and off at least once (180°F). 8. Using the DRB or equivalent scan tool, access Minimum Airflow Idle Speed. 9. The following will then occur: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3078 - Idle air control motor will fully close - Idle spark advance will become fixed - PCM will go open loop enriched - DRB or equivalent scan tool displays engine RPM 10. If idle RPM is within the range shown below, throttle body minimum airflow is set correctly. Odometer Reading Idle RPM Below 1,000 Miles 550 - 1,300 RPM Above 1,000 Miles 600 - 1,300 RPM 11. If idle RPM is above specifications, use the DRB or equivalent scan tool to check idle air control motor operation. If idle air control motor is OK, replace throttle body. If idle air flow is below specification, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash thoroughly after using cleaner. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when is closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 14. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 12. Shut off engine. 13. Remove Air Metering Orifice 6457 or equivalent. Install purge hose. 14. Remove cap from PCV valve. Connect hose to PCV valve. 15. Remove DRB or equivalent scan tool. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Accelerator Pedal: Specifications Accelerator Pedal to Dash Nuts 12 Nm (105 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 3082 Accelerator Pedal: Service and Repair Fig. 35 Accelerator Pedal and Throttle Cable-Front View Fig. 36 Accelerator Pedal and Throttle Cable-Rear View CAUTION: When servicing the accelerator pedal, throttle cable or speed control cable, do not damage or kink the core wire inside the cable sheathing. REMOVAL 1. Working from the engine compartment, remove the throttle control shield. 2. Hold the throttle body throttle lever in the wide open position. - Remove the throttle cable from the throttle body cam. 3. From inside the vehicle, hold up the pedal and remove the cable retainer and throttle cable from the upper end of the pedal shaft (Fig. 35) and (Fig. 36). 4. Working from the engine compartment, remove nuts from accelerator pedal attaching studs (Fig. 35). - Remove assembly from vehicle. INSTALLATION 1. Position accelerator pedal assembly on dash panel. Install retaining nuts. - Tighten retaining nuts to 12 Nm (105 in lb) torque. 2. From inside the vehicle, hold up the pedal and install the throttle cable and cable retainer in the upper end of the pedal shaft. 3. From the engine compartment hold the throttle body lever in the wide open position and install the throttle cable. - Install the throttle control shield. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad Air Cleaner Fresh Air Duct/Hose: Customer Interest Fresh Air Duct - Contacts Hood Insulator Pad NO: 14-05-96 GROUP: Fuel DATE: June 7, 1996 SUBJECT: Wear Marks On Fresh Air Duct And Hood Pad MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES BUILT WITH SPORT/EXPRESSO BUBBLE HOODS AND 2.0L SOHC ENGINES. SYMPTOM/CONDITION: Wear marks on either the fresh air duct or hood pad, due to contact between the two components may be visible. The contact between the fresh air duct and hood pad do not result in a functional problem, but the indentations may be objectional to the customer. PARTS REQUIRED: 1 4669962 Duct, Fresh Air REPAIR PROCEDURE: This bulletin involves the installation of a new fresh air duct which provides additional clearance. 1. Remove the plastic wing nut from the fresh air duct mount. See Illustration. 2. Remove the fresh air duct from the air cleaner box. 3. Install new fresh air duct (P/N 4669962) in the air cleaner box. CAUTION: THE FRESH AIR DUCT MUST BE COMPLETELY SNAPPED INTO THE AIR CLEANER BOX. VERIFY THAT THE DUCT IS FIRMLY IN PLACE. 4. Install the wing nut, while pushing down in the marked area of the fresh air duct. See Illustration. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad > Page 3092 TIME ALLOWANCE: Labor Operation No: 14-10-29-92 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Fresh Air Duct - Contacts Hood Insulator Pad NO: 14-05-96 GROUP: Fuel DATE: June 7, 1996 SUBJECT: Wear Marks On Fresh Air Duct And Hood Pad MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES BUILT WITH SPORT/EXPRESSO BUBBLE HOODS AND 2.0L SOHC ENGINES. SYMPTOM/CONDITION: Wear marks on either the fresh air duct or hood pad, due to contact between the two components may be visible. The contact between the fresh air duct and hood pad do not result in a functional problem, but the indentations may be objectional to the customer. PARTS REQUIRED: 1 4669962 Duct, Fresh Air REPAIR PROCEDURE: This bulletin involves the installation of a new fresh air duct which provides additional clearance. 1. Remove the plastic wing nut from the fresh air duct mount. See Illustration. 2. Remove the fresh air duct from the air cleaner box. 3. Install new fresh air duct (P/N 4669962) in the air cleaner box. CAUTION: THE FRESH AIR DUCT MUST BE COMPLETELY SNAPPED INTO THE AIR CLEANER BOX. VERIFY THAT THE DUCT IS FIRMLY IN PLACE. 4. Install the wing nut, while pushing down in the marked area of the fresh air duct. See Illustration. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad > Page 3098 TIME ALLOWANCE: Labor Operation No: 14-10-29-92 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Fig. 104 Air Intake Duct Fig. 105 Removal/Installation of Air Inlet Duct NOTE: Neon vehicles do not use a heated air inlet system. The PCM adjusts fuel injector pulse width and ignition timing to compensate for different ambient temperatures. NOTE: The air cleaner attaches to a bracket on the rear of the cylinder head. An ambient air duct supplies underhood air for the engine. REMOVAL 1. Remove air intake tube (Fig. 104) from air cleaner and intake manifold (Fig. 105). Fig. 106 Removal/Installation Air Cleaner Front Housing and Element 2. Tighten clasps on top of air cleaner housing. Rotate front of housing forward then lift front away from air cleaner housing (Fig 106). 3. Remove air cleaner element from front housing (Fig. 106). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3102 INSTALLATION 1. Install air cleaner element into front housing. 2. Rotate front of housing forward then lower into place and locate tabs in slots. - Fasten clasps on top of air cleaner housing. - Install air intake duct at air cleaner and intake manifold. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Engine - High Driveability Index Fuels Fuel: Technical Service Bulletins Engine - High Driveability Index Fuels NO: 14-08-97 GROUP: Fuel DATE: Nov. 21, 1997 SUBJECT: Poor Driveability With High DI (Driveability Index) Fuel MODELS: 1996 - 1998 (AB) Ram Van/Wagon 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1996 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (PL) Neon 1997 (PR) Prowler 1996 - 1998 (SR) Viper Roadster/Coupe 1997 - 1998 (TJ) Wrangler 1996 - 1998 (XJ) Cherokee 1995 - 1998 (ZJ) Grand Cherokee SYMPTOM/CONDITION: Long cold start times, warm-up sags, hesitations, and driveway die outs. These symptoms are most noticeable and severe at moderate ambient temperatures between 4 - 27 degrees C (40 - 80 degrees F). DISCUSSION: Gasoline with a high Driveability Index (DI) can cause the above described symptoms. DI is a measure of the gasolines total volatility, or tendency to vaporize completely. A high DI number is less volatile than a low DI number. Most premium gasoline sold in the U.S. has a higher (worse) DI index than regular or mid-grade gasoline. Use of premium gasoline is NOT recommended for vehicles designed to run on 87 (R+M)/2 regular or 89 (R+M)/2 midgrade gasoline. High DI gasolines also cause higher emissions for the same reasons they cause driveability problems. For vehicles that require an octane rating of 91 (R+M)/2, premium is recommended, or possibly required. Using premium fuel with a higher than recommended octane rating is not recommended. Owners who experience fuel related cold start and warm up driveability problems should try a gasoline with the recommended octane rating or different brands of gasoline until they find one that provides good performance. The octane quality of gasoline is only a measure of its resistance to spark knock. The use of higher than recommended octane gasoline under normal operating conditions does NOT improve startability, idle quality, fuel economy, driveability, acceleration, engine durability, or emissions. In fact, most higher octane gasolines available in the U.S. have higher DI values than regular gasoline. Customers are most likely to experience poor driveability with premium gasoline than with regular. Some vehicles, such as Viper, Prowler, 5.9L Grand Cherokee, 2.0L Turbo Talon, and 2.0L DOHC Neon have been specifically designed to take advantage of higher octane. These vehicles may have higher compression ratios, and/or more aggressive spark calibrations which provide optimum performance with the specified higher octane. However, other vehicles which are not specifically designed and calibrated to take advantage of higher octane will not benefit from higher octane. Some vehicles may experience light spark knock in situations such as trailer towing or climbing steep sustained grades. Light knock or "ping" under these conditions is not harmful. However, if the customer is concerned about light knock under these circumstances, the use of 89 (R+M)/2 or even 91 (R+M)/2 premium gasoline may be temporarily warranted. If a vehicle is experiencing heavy spark knock on gasoline with its designed octane rating, this may be an indication of excessive combustion chamber deposits, or some other problem. Combustion chamber deposits can be removed with Mopar Combustion Chamber Conditioner p/n 04318001. Standard diagnostic procedures may help in identifying other potential causes of excessive knock. Some gasoline marketers may advertise that their premium gasoline contains extra detergent additives. Under provisions of the Clean Air Act, ALL gasoline sold in the U.S. must contain effective deposit control additives. Nevertheless, if fuel injector or intake valve deposits are suspected of Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Engine - High Driveability Index Fuels > Page 3107 contributing to poor performance, occasional use of Mopar Fuel Injector Clean Up p/n 04549613 is a much less expensive way to maintain engine cleanliness than regular use of premium gasoline. The charts (Figures 1 & 2) show the negative effects of high DI fuel as related to customer satisfaction. If fuel quality is suspected in causing a customers driveability concern, your zone technical office may be able to provide direction on procedures for fuel sample analysis. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 3108 Fuel: Specifications FUEL REQUIREMENTS The vehicle is designed to meet all emission regulations and provide excellent fuel economy when using high quality unleaded gasoline having a minimum octane rating of 87. The vehicle will operate on fuels ranging from regular unleaded having a minimum posted octane of 87 to premium unleaded with a minimum posted octane of 91. However, mid-grade unleaded fuel with a minimum octane rating of 89 is recommended. The use of premium unleaded gasoline will further improve performance. If the vehicle develops occasional light spark knock (ping) at low engine speeds this is not harmful. However; continued heavy spark knock at high speeds can cause damage and should be corrected immediately. Engine damage as a result of heavy spark knock operation may not be covered by the new vehicle warranty. In addition to using unleaded gasoline with the proper octane rating, those that contain detergents, corrosion and stability additives are recommended. Using gasoline that has these additives will help improve fuel economy, reduce emissions, and maintain vehicle performance. Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. If you experience these problems, try another brand of gasoline before considering service for the vehicle. ADDITIVES & OXYGENATE BLENDS Additives - The use of gasoline containing detergents, corrosion and stability additives is recommended, as these additives will improve fuel economy, reduce emissions, and maintain vehicle performance. Fuel Quality - Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. If you experience these problems, try another brand of gasoline before considering service for the vehicle. Pinging/Knocking - Light knock at low engine speeds is not harmful to your engine. However, continued heavy spark knock at high speeds can cause damage and should be reported to your dealer immediately. CAUTION: Engine damage resulting from operating with a heavy spark knock may not be covered by the new vehicle warranty. GASOLINE/OXYGENATE BLENDS Ethanol - (Ethyl or Grain Alcohol) properly blended, is used as a mixture of 10 percent ethanol and 90 percent gasoline. Gasoline blended with ethanol may be used in your vehicle. Methanol - (Methyl or Wood Alcohol) is used in a variety of concentrations when blended with unleaded gasoline. You may find fuels containing 3 percent or more methanol along with other alcohols called cosolvents. CAUTION: Do not use gasoline containing Methanol. Use of methanol/gasoline blends may result in starting and driveability problems and damage critical fuel system components. Problems that are the result of using methanol/gasoline blends may not be covered by the new vehicle warranty. CLEAN AIR GASOLINE MTBE/ETBE - Many gasoline are now being blended that contribute to cleaner air, especially in those areas of the country where pollution levels are high. These new blends provide a cleaner burning fuel and some are referred to as reformulated gasoline.. MTBE (Methyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline and up to 15 percent MTBE. Gasoline blended with MTBE may be used in your vehicle. ETBE (Ethyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline and up to up to 17 percent ETBE. Gasoline blended with ETBE may be used in your vehicle. ADDITIVE CAUTION: Many materials intended for gum and varnish removal may contain active solvents or similar ingredients that can be harmful to fuel system gasket and diaphragm materials. Indiscriminate use of fuel system cleaning agents should be avoided. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation Fuel Filler Cap: Description and Operation Fig. 4 Pressure Vacuum Filler Cap WARNING: Remove fuel filler tube cap to relieve tank pressure before removing or repairing fuel system components. PURPOSE A pressure-vacuum relief cap seals the fuel tank (Fig. 4). The loss of any fuel or vapor out of the filler tube neck is prevented by the use of a safety filler cap. OPERATION Tightening the cap on the fuel filler tube forms a seal between them. The relief valves in the cap are a safety feature. They prevent possible excessive pressure or vacuum in the tank. Excessive fuel tank pressure could be caused by a malfunction in the system or damage to the vent lines. The seal between the cap and filler tube breaks when the cap is removed. Breaking the seal relieves fuel tank pressure. Pressure Release The cap releases only under significant pressure 10.9 to 13.45 kPa (1.58 to 1.95 psi). Vacuum Release The vacuum release for all gas caps is between 0.97 and 2.0 kPa (0.14 and 0.29 psi). Replacement If the filler cap needs replacement, only use an original equipment or equivalent unit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3116 Fuel Pressure Release: Service and Repair Fig. 1 Fuel Pressure Test Port--Typical Fig. 12 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail Fig. 1. 4. Place open end of fuel pressure release hose Special Tool number C-4799-1, into an approved gasoline container. 5. Connect other end of hose C-4799-1 to fuel pressure test port Fig. 2. - Fuel pressure will bleed off through the hose into the gasoline container. (Fuel gauge C-4799-A contains hose C-4799-1.) 6. Replace Pressure test port cap when finished releasing pressure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Engine Controls/Emissions - Manual Revisions Fuel Injector: Technical Service Bulletins Engine Controls/Emissions - Manual Revisions NUMBER: 26-06-97D GROUP: Miscellaneous DATE: June, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1996 2.0L, 2.4L, 2.5L, 3.3L, 3.8L Engine Diagnostic Manual - Publication Number 81-699-95012 DESCRIPTION OF CHANGES Revisions to the diagnostic procedures Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Engine Controls/Emissions - Manual Revisions > Page 3121 343 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Engine Controls/Emissions - Manual Revisions > Page 3122 354 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Engine Controls/Emissions - Manual Revisions > Page 3123 355 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Engine Controls/Emissions - Manual Revisions > Page 3124 357 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Engine Controls/Emissions - Manual Revisions > Page 3125 359 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Engine Controls/Emissions - Manual Revisions > Page 3126 359A Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Engine Controls/Emissions - Manual Revisions > Page 3127 359B Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Engine Controls/Emissions - Manual Revisions > Page 3128 441 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Engine Controls/Emissions - Manual Revisions > Page 3129 443 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Engine Controls/Emissions - Manual Revisions > Page 3130 445 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Engine Controls/Emissions - Manual Revisions > Page 3131 517 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Engine Controls/Emissions - Manual Revisions > Page 3132 517A Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Engine Controls/Emissions - Manual Revisions > Page 3133 517B Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Engine Controls/Emissions - Manual Revisions > Page 3134 Fuel Injector: Technical Service Bulletins Fuel Injector Connector - Orientation NO: 08-38-95 GROUP: Electrical DATE: Sep. 8, 1995 SUBJECT: Fuel Injector Connector Orientation MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.0L SOHC ENGINE DISCUSSION: When servicing the engine, intake air duct or injectors, the number three and four injector connectors must be orientated at a 450 to 800 opposing angle. If the connectors are left in the 12:00 o'clock (straight up) position, the wiring may be chafed by the air intake duct resulting in an open circuit condition causing an engine miss. See illustration for proper connector orientation. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Page 3135 Fuel Injector: Specifications Injector resistance should be between 10 ohms and 16 ohms. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Page 3136 Injector #1 Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Fuel Injectors Description Fuel Injector: Description and Operation Fuel Injectors Description Fig. 4 Fuel Injector Fig. 5 Fuel Injector Location-Typical OPERATION The fuel injectors are 12 ohm electrical solenoids (Fig. 4). The injector contains a pintle that closes off an orifice at the nozzle end. When electric current is supplied to the injector the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in the shape of a hollow cone. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber. The injectors are positioned in the intake manifold with the nozzle ends directly above the intake valve port (Fig. 5). CIRCUIT OPERATION Circuit A14 is a bus bar in the Power Distribution Center (PDC), and connects to battery voltage. The contact side of the Automatic Shut Down ( ASD) relay connects circuit A14 and circuit A142. A 20 Amp fuse in the PDC protects circuits A14 and A142. Circuit A14 also supplies voltage to the coil side of the ASD relay. The Powertrain Control Module (PCM) controls the ground circuit for the coil side of the ASD relay on circuit K51. Circuit K51 connects to cavity 67 of the PCM connector. Circuit A142 supplies voltage for the fuel injectors. The PCM controls the ground circuit of each injector. Circuit K11 is the ground circuit for Injector #1. Circuit K11 connects to cavity 13 of the PCM. - Circuit K12 is the ground circuit for Injector #2. Circuit K12 connects to cavity 17 of the PCM. - Circuit K13 is the ground circuit for Injector #3. Circuit K13 connects to cavity 7 of the PCM. - Circuit K14 is the ground circuit for Injector #4. Circuit K14 connects to cavity 16 of the PCM. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Fuel Injectors Description > Page 3139 Fuel Injector: Description and Operation Injector Control Circuit Trouble Code Name of Code: Injector Control Circuit When Monitored: With battery voltage greater than 12 volts, the auto shutdown relay energized, injector pulse width less than 10 ms, and engine speed less than 3,000 rpm. Set Condition: This trouble code takes 0.64 to 10.0 seconds to set when no inductive kick is sensed 0.18 ms after injector turn off, and with no other injectors on. Theory of Operation: Fuel injectors are high-impedance solenoids controlled by the PCM. Battery voltage is supplied by the ASD relay. The injector on time (pulse width) is controlled by the amount of time the PCM grounds the injector control circuit. By varying this time, more or less fuel is allowed to flow through the injector. Possible Causes: - Open or shorted injector driver circuit - Open injector - Open ASD supply at injector - PCM failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Helpful Information Fuel Injector: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, ASD relay, generator, and the upstream and downstream heated oxygen sensors. The PCM controls the ground circuit for each of the components powered by circuit A142. The injectors operate in sequence. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Helpful Information > Page 3142 Fuel Injector: Testing and Inspection Resistance Test Related Images Check resistance between the injector terminals. Resistance should be between 10 and 16 ohms. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Helpful Information > Page 3143 Fuel Injector: Testing and Inspection Diagnostic Chart Fuel Injector Diagnosis For fuel injector diagnosis, refer to the Fuel Injector Diagnosis charts. For poor fuel economy diagnosis or engine miss also consider transmission problems. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Helpful Information > Page 3144 Fuel Injector: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 3145 Fuel Injector: Service and Repair Fig. 27 Fuel Rail and Injectors REMOVAL 1. Disconnect negative cable from battery. 2. Release fuel system pressure. 3. Disconnect fuel supply tube from rail. 4. Disconnect electrical connectors from fuel injectors (Fig. 27). 5. Remove fuel rail mounting screws. 6. Lift rail off of intake manifold. Cover the fuel injector openings in the intake manifold. Fig. 28 Fuel Injector Retainer 7. Remove fuel injector retainer (Fig. 28). Fig. 29 Fuel Injector 0-Rings 8. Pull injector out of fuel rail. Replace fuel injector 0-rings (Fig. 29). INSTALLATION 1. Apply a light coating of clean engine oil to the upper 0-ring. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 3146 2. Install injector in cup on fuel rail. 3. Install retaining clip. 4. Apply a light coating of clean engine oil to the 0-ring on the nozzle end of each injector. 5. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail mounting screws to 22.5 Nm ± 3 Nm (200 ± 30 in lb). 6. Attach electrical connectors to fuel injectors. 7. Conned fuel supply tube to fuel rail. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation Fuel Line Coupler: Description and Operation QUICK-CONNECT FITTINGS Fuel tubes connect fuel system components with plastic quick-connect fuel fittings. The fitting contains non-serviceable 0-ring seals (Fig. 6). CAUTION: Quick-connect fittings are not serviced separately. Do not attempt to repair damaged quick-connect fittings or fuel tubes. Replace the complete fuel tube/quick-connect fitting assembly. The quick-connect fitting consists of the 0-rings, retainer and casing (Fig. 6). When the fuel tube enters the fitting, the retainer locks the shoulder of the nipple in place and the 0-rings seal the tube. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Page 3150 Fuel Line Coupler: Service and Repair Fig. 14 Plastic Quick-Connect Fitting/Fuel Tube Connection WARNING: Release fuel system pressure before disconnecting a quick-connect fittings. Refer to the fuel pressure release procedure. NOTE: When disconnecting a quick-connect fitting, the retainer will remain on the fuel tube nipple. REMOVAL 1. Disconnect negative cable from battery. 2. Perform Fuel Pressure Release Procedure. 3. Squeeze retainer tabs together and pull fuel tube/quick-connect fitting assembly off of fuel tube nipple. The retainer will remain on fuel tube. CAUTION: Never install a quick-connect fitting without the retainer being either on the fuel tube or already in the quick-connect fitting. In either case, ensure the retainer locks securely into the quick-connect fitting by firmly pulling on fuel tube and fitting to ensure it is secured. INSTALLATION 1. Using a clean lint free cloth clean the fuel tube nipple and retainer. 2. Prior to connecting the fitting to the fuel tube, coat the fuel tube nipple with clean 30 weight engine oil. 3. Push the quick-connect fitting over the fuel tube until the retainer seats and a click is heard. 4. The quick-connect fitting has windows in the sides of the casing. - When the fitting completely attaches to the fuel tube, the retainer locking ears and the fuel tube shoulder are visible in the windows. - If they are not visible, the retainer was not properly installed (Fig. 14). - Do not rely upon the audible click to confirm a secure connection. CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for either 7 minutes, until the test is stopped, or until the ignition switch is turned to the Off position. 5. Use the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation Fuel Pressure Regulator: Description and Operation Fig. 2 Side View-Filter/Regulator A combination fuel filter and fuel pressure regulator is used on all gas powered engines. It is located on the top of the fuel pump module. A separate frame mounted fuel filter is not used. Fuel Pressure Regulator Operation: The pressure regulator is a mechanical device that is calibrated to maintain fuel system operating pressure of approximately 338 kPa (49 psi) at the fuel injectors. It contains a diaphragm, calibrated springs and a fuel return valve. The internal fuel filter (Fig. 2) is also part of the assembly Fuel is supplied to the filter/regulator by the electric fuel pump through an opening tube at the bottom of filter/regulator. The fuel pump module contains a check valve to maintain some fuel pressure when the engine is not operating. This will help to start the engine. If fuel pressure at the pressure regulator exceeds approximately 49 psi, an internal diaphragm closes and excess fuel pressure is routed back into the tank through the pressure regulator. A separate fuel return line is not used with any gas powered engine. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 3154 Fuel Pressure Regulator: Service and Repair Fig. 18 Locking Spring Tab WARNING: The fuel system is under a constant pressure, even with engine off before servicing the fuel filter/fuel pressure regulator, the fuel system pressure must be released. NOTE: The fuel filter/fuel pressure regulator is located on the top of fuel pump module. Fuel pump module removal is not necessary. REMOVAL 1. Raise vehicle on hoist. 2. Disconnect fuel supply line at the Filter/Regulator nipple. 3. Depress locking spring tab on side of Fuel/Regulator (Fig. 18) and rotate 9O° counter-clockwise and pull out. NOTE: Make sure that the upper and lower 0-rings are on the Filter/Regulator assembly, and lightly lubricate the 0-rings with engine oil. Fig. 19 Spring Tab In Locating Slot INSTALLATION 1. Insert filter/regulator into the opening in the fuel pump module, align the two hold down tabs with the flange. 2. While applying downward pressure, rotate the Filter/Regulator clockwise until the the spring tab engages the locating slot (Fig. 19). 3. Connect the fuel line to the Filter/Regulator. 4. Lower vehicle from hoist. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Locations Typical -- SOHC Shown Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Typical -- SOHC Shown Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Fuel Pump Relay Fig. 15 Power Distribution Center (PDC) The fuel pump relay is located in the Power Distribution Center (PDC). The inside top of the PDC cover has a label showing relay and fuse location. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3166 Fuel Pump Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Description and Operation > Fuel Pump Relay Operation Fuel Pump Relay: Description and Operation Fuel Pump Relay Operation NAME OF CODE: Fuel Pump Relay Control Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the fuel pump relay control circuit. THEORY OF OPERATION: The fuel pump relay controls the 12-volt source to the fuel pump. If the vehicle is equipped with a power distribution center, the relay is located in the Power Distribution Center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the RUN or CRANK position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the fuel pump relay control circuit ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Fuel pump relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Description and Operation > Fuel Pump Relay Operation > Page 3169 Fuel Pump Relay: Description and Operation Fuel Pump Relay Control Circuit Trouble Code Name of Code: Fuel Pump Relay Control Circuit When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: An open or shorted condition is detected in the fuel pump relay control circuit. Theory of Operation: The fuel pump relay controls the 12-volt source to the fuel pump. If the vehicle is equipped with a power distribution center, the relay is located in the PDC. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "run position". The circuit is completed when the other side of the relay coil is grounded by the powertrain control module. The PCM grounds the relay when the ignition switch is in either the run or crank position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the fuel pump relay control circuit ground. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - Fuel pump relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Description and Operation > Page 3170 Fuel Pump Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30 is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85 -- The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86 supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A -- When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87 When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Description and Operation > Page 3171 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Complete testing for this system or component can be found at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications Fuel Rail: Specifications Fuel Rail Bolts 23 Nm (195 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3175 Fuel Rail: Description and Operation Fig. 3 Fuel Rail-Typical The fuel rail supplies the necessary fuel to each individual fuel injector and is mounted to the intake manifold (Fig. 3). The fuel pressure regulator is no longer mounted to the fuel rail on any engine. It is now located on the fuel tank mounted fuel pump module. The fuel rail is not repairable. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair Fuel Filler Hose: Service and Repair Fig. 33 Fuel Filler Neck REMOVAL 1. Loosen fuel filler tube cap. 2. Remove fuel filler neck screws (Fig. 33). 3. Disconnect fuel fill vapor tube. 4. Disconnect fuel filler tube from fuel tank. Remove filler neck. INSTALLATION 1. Reverse for installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > General Description Fuel Gauge Sender: Description and Operation General Description Fig. 10 Level Sensor Diagnosis OPERATION The fuel gauge sending unit is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and two variable resistors (tracks). These two tracks are used to send two different electrical signals. One is used for fuel gauge operation and the other is for OBD II emission requirements. Track 1 fuel gauge operation: As the fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge on the instrument panel to read full. As the fuel level decreases, the float and arm move down. This increases the sending unit resistance, causing the fuel gauge on the instrument panel to read empty Track 2-OBD II emission requirements: A variable voltage signal is sent to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes if the fuel level in the tank is less than 15 percent of its rated capacity. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > General Description > Page 3184 Fuel Gauge Sender: Description and Operation Related Trouble Codes and Set Conditions Fuel Level Sending Unit Volts Too High Name of Code: Fuel Level Sending Unit Volts Too High When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes above a calculated value. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel systems monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Open sensor signal circuit - Fuel level sending unit failure - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Fuel Level Sending Unit Volts Too Low Name of Code: Fuel Level Sending Unit Volts Too Low When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes below 0.10 volts. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel system monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Sensor signal circuit shorted to ground - Fuel level sending unit failure - Loss of fuel ignition switch output voltage - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Page 3185 Fuel Gauge Sender: Testing and Inspection Fig. 10 Level Sensor Diagnosis This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. To test the level sensor, connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector. Move the float lever to the positions shown in the resistance chart. Record the resistance at each point. Replace the level sensor if the resistance is not within specifications. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Page 3186 Fuel Gauge Sender: Service and Repair Fig. 21 Fuel Pump/Level Sensor Electrical Connector NOTE: Remove fuel pump module prior to beginning this procedure. REMOVAL 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector. Fig. 22 Wire Terminal Locking Wedge 2. Pull off blue locking wedge. Fig. 23 Wire Terminal Locking Finger 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Page 3187 Fig. 24 Removing Wires From Connector 4. Push level sensor signal and ground terminals out of the connector. Fig. 25 Loosening Level Sensor 5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Fig. 26 Level Sensor Removal/Installation 6. Push level sensor down slightly. - Ensure tab at bottom of sensor locks in place. 7. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 8. Install locking wedge on connector. 9. Push connector up into bottom of fuel pump module electrical connector. 10. Install fuel pump module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Specifications Fuel Tank Mounting Straps: Specifications Fuel Tank Straps torque = 23 Nm (250 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Description and Operation Fuel Tank Unit: Description and Operation Fig. 1 Fuel Pump Module NOTE: The fuel pump module is installed in the top of the fuel tank (Fig. 1). The fuel pump module contains the following: Electric fuel pump - Fuel pump reservoir - Inlet strainer - Fuel filter/pressure regulator - Fuel gauge sending unit - Fuel supply line connection The inlet strainer, fuel pressure regulator and fuel level sensor are the only serviceable items. If the fuel pump requires service, replace the fuel pump module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Description and Operation > Page 3194 Fuel Tank Unit: Service and Repair Fig. 16 Fuel Pump Module Removal WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. never smoke while servicing the vehicle. REMOVAL 1. Drain the fuel. WARNING: The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed. 2. Disconnect fuel line from fuel pump module by depressing quick connect retainers with thumb and fore finger. 3. Slide fuel pump module electrical connector lock to unlock. 4. Disconnect the electrical connection from the fuel pump module by pushing down on connector retainer and pulling connector off of module. 5. Use a transmission jack to support the fuel tank. remove bolts from fuel tank straps. 6. Lower tank slightly Fig. 17 Fuel Tank Locknut 7. Use Special Tool 6856 to remove fuel pump module locknut (Fig. 17). 8. Remove fuel pump and 0-ring seal from tank. Discard old seal. INSTALLATION 1. Wipe seal area of tank clean and place a new seal in position in the tank opening. 2. Position fuel pump in the tank. Make sure the alignment tab on the underside of the fuel pump module flange sits in the notch on the fuel tank. 3. Position the locknut over the fuel pump module. 4. Tighten the locknut using Special Tool 6856 to 55 Nm (40.5 ft lb) (Fig. 17). CAUTION: Over tightening the pump lock ring may result in a leak. 5. Fill fuel tank. Check for leaks. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications IAC Motor-To-Throttle Body Bolts 7 Nm (60 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3198 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3199 Idle Air Control Motor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Idle Air Control Motor Idle Speed/Throttle Actuator - Electronic: Description and Operation Idle Air Control Motor THEORY OF OPERATION: The idle air control (IAC) motor is used by the Powertrain Control Module (PCM) to help regulate idle speed. The motor controls the amount of air allowed to bypass the throttle blade. The PCM controls the motor using four driver circuits to position the stepper motor. CIRCUIT OPERATION The Powertrain Control Module (PCM) operates the Idle Air Control (IAC) motor through 4 circuits K39, K40, K59, and K60. Each circuit connects to separate cavities in the PCM connector. Circuit K39 connects to cavity 57 of the PCM connector. - Circuit K40 connects to cavity 48 of the PCM connector. - Circuit K59 connects to cavity 58 of the PCM connector. - Circuit K60 connects to cavity 49 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Idle Air Control Motor > Page 3202 Idle Speed/Throttle Actuator - Electronic: Description and Operation Related Trouble Codes Idle Air Control Motor Circuits Name of Code: Idle Air Control (IAC) Motor Circuits When Monitored: At key on and battery voltage greater than 11.5 volts. Set Condition: The PCM senses a short to ground or battery voltage on any of the four IAC driver circuits for 2.75 seconds while the IAC motor is active. Theory of Operation: The idle air control motor is used by the PCM to regulate idle speed. The motor controls the amount of air allowed to bypass the throttle blade. The PCM controls the motor using four driver circuits to position the stepper motor. Possible Causes: - Driver circuit shorted to ground - Driver circuit shorted to battery voltage - Driver circuits shorted together - Failed PCM - Shorted AC motor - Connector terminals - Connector wires Target Idle Not Reached Name of Code: Target Idle Not Reached When Monitored: With the engine idling and in Drive if automatic. There must not be a MAP sensor trouble code or a throttle position sensor trouble code. Set Condition: Engine idle is not within 200 rpm above or 100 rpm below target idle for 14 seconds. Three separate failures are required to set a bad trip. Two bad trips are required to set code. Theory of Operation: The Idle Air Control (IAC) motor is used by the PCM to help regulate idle speed. The motor controls the amount of air allowed to bypass the throttle blade. The PCM controls the motor using four driver circuits to position the stepper motor. Possible Causes: - Driver circuit shorted to ground - Driver circuit shorted to battery - Driver circuits shorted together - Failed PCM - Shorted IAC motor - Carbon deposits - Driver circuit open - Connector terminals - Connector wires - Large vacuum leak - Throttle misadjusted (min. airflow RPM wrong) - Throttle not closing reliably Vacuum Leak Found (Idle Air Control Motor Fully Seated) Name of Code: Vacuum Leak Found (Idle Air Control (IAC) Motor Fully Seated) When Monitored: With the engine running. Set Condition: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Idle Air Control Motor > Page 3203 The MAP sensor signal does not correlate to the TP sensor signal. Theory of Operation: The powertrain control module (PCM) monitors the MAP signal as well as the TP sensor signal. The vacuum reading decreases as throttle opening increases proportionally. The PCM compares the two values to verify the relation between the two signals. Possible Causes: - Vacuum leak - Faulty MAP sensor - Faulty TP sensor - Powertrain control module failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Page 3204 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Page 3205 Idle Speed/Throttle Actuator - Electronic: Service and Repair Fig. 95 Servicing Idle Air Control Motor CAUTION: When servicing throttle body components, always reassemble components with new 0-rings and seals where applicable. Never use lubricants on 0-rings or seals, damage may result. If assembly of component is difficult, use water to aid assembly. Use care when removing hoses to prevent damage to hose or hose nipple. REMOVAL 1. Disconnect negative cable from battery 2. Remove electrical connector from idle air control motor and throttle position sensor. 3. Remove the EVAP purge hose from the throttle body. 4. Remove throttle body. 5. Remove idle air control motor mounting screws (Fig. 95). 6. Remove motor from throttle body Ensure the 0-ring is removed with the motor. INSTALLATION 1. The new idle air control motor has a new 0-ring installed on it. - If pintle measures more than 1 inch (25 mm) it must be retracted. - Use the DRB Idle Air Control Motor Open/Close Test to retract the pintle (battery must be connected). 2. Carefully place idle air control motor into throttle body 3. Install mounting screws. Tighten screws to 7 Nm (60 in lb) torque. 4. Install throttle body. 5. Connect electrical connector to idle air control motor and throttle position sensor. 6. Connect the EVAP purge hose to the throttle body nipple. 7. Connect negative cable to battery. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig. 15 Power Distribution Center (PDC) Auto Shutdown Relay The relay is located in the Power Distribution Center (PDC) (Fig. 15). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3209 Auto Shutdown Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Automatic Shut Down Relay Automatic Shut Down (ASD) Relay: Description and Operation Automatic Shut Down Relay Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. CIRCUIT OPERATION The Automatic Shut Down (ASD) relay is located in the Power Distribution Center (PDC). Power for the coil and contact side of the relay is supplied on circuit A14. This circuit is HOT at all times and protected by a 20 Amp fuse located in the PDC. The Powertrain Control Module (PCM) controls the ground path for the coil side of the relay on circuit K51. This circuit connects to cavity 67 of the PCM. When the PCM supplies the ground path on circuit K51 the contacts in the relay CLOSE connecting circuits A14 and A142. The A142 circuit is spliced and supplies power to the generator, fuel injectors, PCM, ignition coil, and heated oxygen sensors. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Automatic Shut Down Relay > Page 3212 Automatic Shut Down (ASD) Relay: Description and Operation Related Trouble Codes and Set Conditions Auto Shutdown Relay Control Circuit Name of Code: Auto Shutdown Relay Control Circuit When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: An open or shorted condition is detected in the auto shutdown relay control circuit. Theory of Operation: The automatic shutdown relay (ASD) controls the 12 volt source to the fuel injectors, ignition coil(s), oxygen sensors, and the generator. The relay is located in the power distribution center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the run position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the run or crank position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the ASD relay control circuit ground. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - Auto shutdown relay control circuit open or shorted - Inoperative circuit driver in powertrain control module - PCM failure - Connector terminals - Connector wires No ASD Relay Output Sensed at PCM Name of Code: No Auto Shutdown (ASD) Relay Output Voltage At PCM When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: No voltage sensed at the powertrain control module when the auto shutdown relay is energized. Theory of Operation: When the ASD relay is energized, the relay contacts connect the fused B(+) circuit to the relay output circuit. The powertrain control module is connected in parallel with the ASD relay output circuit. This connection provides the PCM with a circuit to monitor the ASD relay output state. Whenever the PCM energizes the ASD relay, it checks the feedback circuit to ensure voltage is present at the ASD relay output. If voltage is not present, a trouble code is set. Possible Causes: - ASD relay output circuit open - Fused B(+) circuit open - ASD relay - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 Amp fuse located in the PDC. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 3215 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 3216 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 3217 Automatic Shut Down (ASD) Relay: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 Fuel Pump Relay Fig. 15 Power Distribution Center (PDC) The fuel pump relay is located in the Power Distribution Center (PDC). The inside top of the PDC cover has a label showing relay and fuse location. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3222 Fuel Pump Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Fuel Pump Relay Operation Fuel Pump Relay: Description and Operation Fuel Pump Relay Operation NAME OF CODE: Fuel Pump Relay Control Circuit WHEN MONITORED: With the ignition key ON and battery voltage greater than 10 volts. SET CONDITION: An open or shorted condition is detected in the fuel pump relay control circuit. THEORY OF OPERATION: The fuel pump relay controls the 12-volt source to the fuel pump. If the vehicle is equipped with a power distribution center, the relay is located in the Power Distribution Center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the RUN or CRANK position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the fuel pump relay control circuit ground. POSSIBLE CAUSES: - Relay coil open or shorted - Fused ignition switch output circuit open - Fuel pump relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Fuel Pump Relay Operation > Page 3225 Fuel Pump Relay: Description and Operation Fuel Pump Relay Control Circuit Trouble Code Name of Code: Fuel Pump Relay Control Circuit When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: An open or shorted condition is detected in the fuel pump relay control circuit. Theory of Operation: The fuel pump relay controls the 12-volt source to the fuel pump. If the vehicle is equipped with a power distribution center, the relay is located in the PDC. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "run position". The circuit is completed when the other side of the relay coil is grounded by the powertrain control module. The PCM grounds the relay when the ignition switch is in either the run or crank position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the fuel pump relay control circuit ground. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - Fuel pump relay control circuit is open or shorted - Inoperative circuit driver in powertrain control module - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Page 3226 Fuel Pump Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30 is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85 -- The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86 supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A -- When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87 When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Page 3227 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Complete testing for this system or component can be found at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fig. 15 Power Distribution Center (PDC) Auto Shutdown Relay The relay is located in the Power Distribution Center (PDC) (Fig. 15). The PDC is located next to the battery in the engine compartment. For the location of the relay within the PDC refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3231 Auto Shutdown Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Automatic Shut Down Relay Automatic Shut Down (ASD) Relay: Description and Operation Automatic Shut Down Relay Fig. 20 Power Distribution Center (PDC) PURPOSE The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay. The fuse also protects the power circuit for the fuel pump relay and pump. The fuse is located in the PDC. The PCM controls the ASD relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the OFF position. - When the ignition switch is in ON or START, the PCM monitors the crankshaft and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). - If the PCM does not receive crankshaft and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay The ASD relay is located in the PDC (Fig. 20). The inside top of the PDC cover has a label showing relay and fuse identification. CIRCUIT OPERATION The Automatic Shut Down (ASD) relay is located in the Power Distribution Center (PDC). Power for the coil and contact side of the relay is supplied on circuit A14. This circuit is HOT at all times and protected by a 20 Amp fuse located in the PDC. The Powertrain Control Module (PCM) controls the ground path for the coil side of the relay on circuit K51. This circuit connects to cavity 67 of the PCM. When the PCM supplies the ground path on circuit K51 the contacts in the relay CLOSE connecting circuits A14 and A142. The A142 circuit is spliced and supplies power to the generator, fuel injectors, PCM, ignition coil, and heated oxygen sensors. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Description and Operation > Automatic Shut Down Relay > Page 3234 Automatic Shut Down (ASD) Relay: Description and Operation Related Trouble Codes and Set Conditions Auto Shutdown Relay Control Circuit Name of Code: Auto Shutdown Relay Control Circuit When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: An open or shorted condition is detected in the auto shutdown relay control circuit. Theory of Operation: The automatic shutdown relay (ASD) controls the 12 volt source to the fuel injectors, ignition coil(s), oxygen sensors, and the generator. The relay is located in the power distribution center (PDC). One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the run position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay when the ignition switch is in either the run or crank position and engine RPM is detected. If engine RPM is not detected, the PCM will remove the ASD relay control circuit ground. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - Auto shutdown relay control circuit open or shorted - Inoperative circuit driver in powertrain control module - PCM failure - Connector terminals - Connector wires No ASD Relay Output Sensed at PCM Name of Code: No Auto Shutdown (ASD) Relay Output Voltage At PCM When Monitored: With the ignition key on and battery voltage greater than 10 volts. Set Condition: No voltage sensed at the powertrain control module when the auto shutdown relay is energized. Theory of Operation: When the ASD relay is energized, the relay contacts connect the fused B(+) circuit to the relay output circuit. The powertrain control module is connected in parallel with the ASD relay output circuit. This connection provides the PCM with a circuit to monitor the ASD relay output state. Whenever the PCM energizes the ASD relay, it checks the feedback circuit to ensure voltage is present at the ASD relay output. If voltage is not present, a trouble code is set. Possible Causes: - ASD relay output circuit open - Fused B(+) circuit open - ASD relay - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 20 Amp fuse located in the PDC. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 3237 Automatic Shut Down (ASD) Relay: Testing and Inspection Fuel Pump & ASD Relay Test Fig. 29 ASD And Fuel Pump Relay Terminals The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 3238 WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Helpful Information > Page 3239 Automatic Shut Down (ASD) Relay: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Description and Operation Rollover Valve: Description and Operation This vehicle has two rollover valves. One in the fuel filler tube and the other on the top of the fuel tank. The valves prevent fuel flow through the fuel tank vent valve hoses should the vehicle rollover. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Description and Operation > Page 3243 Rollover Valve: Testing and Inspection Gently shake the valve -- up and down. If the float valve can be heard moving -- knocking -- then the valve is OK. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Service and Repair > Fuel Filler Tube Rollover Valve Rollover Valve: Service and Repair Fuel Filler Tube Rollover Valve Fig. 34 Fuel Filler Tube Rollover Valve NOTE: The rollover valve is mounted in the fuel filler tube (Fig. 34). REMOVAL 1. To release fuel tank pressure, remove the fuel filler tube cap. 2. Disconnect vapor tube from rollover valve. 3. Using a straight screwdriver, pry the valve out of the grommet in the fuel filler tube. INSTALLATION 1. Apply a light coating of power steering fluid to the grommet. 2. Install valve in grommet. 3. Attach vapor tube to valve. 4. Install fuel filler tube cap. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Service and Repair > Fuel Filler Tube Rollover Valve > Page 3246 Rollover Valve: Service and Repair Fuel Tank Rollover Valve Replacement REMOVAL 1. To release fuel tank pressure, remove the fuel filler tube cap. 2. Remove fuel tank. Refer to procedure. 3. Disconnect vapor tube from rollover valve. 4. Using a straight screwdriver, pry the valve out of the grommet in the fuel filler tube. INSTALLATION 1. Apply a light coating of power steering fluid to the grommet. 2. Install valve in grommet. 3. Attach vapor tube to valve. 4. Install fuel tank. Refer to procedure. See: Fuel Tank/Service and Repair/Fuel Tank Replacement 5. Install fuel filler tube cap. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: Customer Interest Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 3256 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: All Technical Service Bulletins Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 3262 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3265 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3266 Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3267 Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS mounts to the throttle body and connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- from 0.38 to 1.03 volts. - AT Wide open throttle -- 3.1 to 4.0 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). CIRCUIT OPERATION From the Powertrain Control Module (PCM) circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 3270 Throttle Position Sensor: Description and Operation Related Trouble Codes & Set Conditions Throttle Position Sensor Voltage High Name of Code: Throttle Position Sensor Voltage High When Monitored: With the ignition on. Set Condition: TP sensor voltage at PCM cavity 35 goes above 4.5 volts for 0.704 seconds. Theory of Operation: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 35. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. Possible Causes: - Sensor signal circuit open - Throttle position sensor failure - Sensor ground circuit open - PCM failure - Connector terminals - Connector wires Throttle Position Sensor Voltage Low NAME OF CODE: Throttle Position Sensor Voltage Low WHEN MONITORED: With the ignition ON. SET CONDITION: The Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 35 goes below 0.2 volt for 0.704 seconds, or MPH is above 20, RPM is above 1500, and vacuum is below 2" with TP sensor voltage less than 0.5 volt for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Throttle position sensor failure - Loss of 5-volt supply TPS Voltage Does Not Agree With MAP Name of Code: TPS Voltage Does Not Agree with MAP When Monitored: With the engine running and no MAP sensor or TP sensor trouble codes. Set Condition: The powertrain control module (PCM) performs two separate tests on the TP sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 mph and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 4 continuous seconds. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 3271 Theory of Operation: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from the PCM. The sensor ground is provided by the PCM. Possible Causes: - Failed powertrain control module - Connector wires - TP sensor failure - Vehicle speed - Mechanical failure - MAP sensor - Connector terminals Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3274 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor around terminal. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately 0.38 volts to 1.03 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.0 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3275 Throttle Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3276 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3277 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (20 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 180496 > Feb > 96 > Throttle Body/TPS MIL ON/DTC MIL 24 Set Throttle Body: Customer Interest Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 180496 > Feb > 96 > Throttle Body/TPS MIL ON/DTC MIL 24 Set > Page 3286 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Body: All Technical Service Bulletins Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 3292 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 3293 Throttle Body: Specifications Throttle Body Mounting Bolts 23 Nm (200 in lb) Throttle Control Shield 5.6 Nm (50 in lb) IAC Motor-To-Throttle Body Bolts 7 Nm (30 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 3294 Throttle Body: Testing and Inspection Fig. 31 PCV Vacuum Nipple 1. Turn ignition key off. 2. Disconnect the PCV valve hose from the intake manifold nipple (Fig. 31). Cap the PCV vacuum nipple. Fig. 32 Purge Hose 3. Disconnect purge hose from the nipple on the throttle body (Fig. 32). Fig. 33 Orifice 6457 Attached To Purge Nipple 4. Use a piece of hose to attach Air Metering Orifice 6457 (0.125 in. orifice) or equivalent, to the purge nipple on the throttle body (Fig. 33). 5. Ensure that all accessories are off. 6. Connect the DRB or equivalent scan tool to the data link connector inside the passenger compartment. 7. Run engine in Park or Neutral until the cooling fan has cycled on and off at least once (180°F). 8. Using the DRB or equivalent scan tool, access Minimum Airflow Idle Speed. 9. The following will then occur: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 3295 - Idle air control motor will fully close - Idle spark advance will become fixed - PCM will go open loop enriched - DRB or equivalent scan tool displays engine RPM 10. If idle RPM is within the range shown below, throttle body minimum airflow is set correctly. Odometer Reading Idle RPM Below 1,000 Miles 550 - 1,300 RPM Above 1,000 Miles 600 - 1,300 RPM 11. If idle RPM is above specifications, use the DRB or equivalent scan tool to check idle air control motor operation. If idle air control motor is OK, replace throttle body. If idle air flow is below specification, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash thoroughly after using cleaner. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when is closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 14. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 12. Shut off engine. 13. Remove Air Metering Orifice 6457 or equivalent. Install purge hose. 14. Remove cap from PCV valve. Connect hose to PCV valve. 15. Remove DRB or equivalent scan tool. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Automatic Transmission Throttle Body: Service and Repair Automatic Transmission Fig. 88 Throttle Body Cables Attachment to Throttle Body Fig. 89 Disconnecting Throttle Cable REMOVAL 1. Remove throttle cable cover. 2. Remove throttle body cables using the following procedures. 3. Remove throttle cable from throttle body cam (Fig. 88) and (Fig. 89). 4. Compress the retaining tabs on the cable and slide cable out of bracket (Fig. 89). Fig. 90 Transmission Kickdown Cable Connector 5. Hold throttle lever in the wide open position. - Using finger pressure only remove kickdown cable by PUSHING connector off the lever nail head (Fig. 88) and (Fig. 90). DO NOT try to pull connector off perpendicular to the lever. 6. Compress the retaining tabs on the cable and slide cable out of bracket (Fig. 89). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Automatic Transmission > Page 3298 Fig. 91 Speed Control Cable Connector 7. if equipped with speed control, hold throttle lever in the wide open position. Using finger pressure only -- remove speed control cable by PUSHING connector off the lever nail head (Fig. 88) and (Fig. 91). DO NOT try to pull connector off perpendicular to the lever. 8. Compress the retaining tabs on the cable and slide cable out of bracket (Fig. 89). 9. Remove 2 screws holding cable mounting bracket and support bracket. 10. Remove TPS connection 11. Remove Idle Air Control motor connector. 12. Remove EVAP purge hose. 13. Remove throttle body mounting bolts. Remove throttle body. Fig. 92 Re-Usable Throttle Body Gasket 14. The rubber 0-ring gasket on the intake manifold is reusable. Wipe the 0-ring clean before installing throttle body (Fig. 92). INSTALLATION 1. Install throttle body on intake manifold. Tighten mounting bolts to 23 Nm (200 in lb). 2. Attach cable mounting bracket and support bracket with 2 screws. 3. Connect electrical connection to throttle body. 4. Connect the EVAP purge hose. 5. Install cable housing(s) retainer tabs into bracket. 6. Install throttle body cables using the following procedures. 7. From the engine compartment, rotate the throttle lever forward to the wide open position and install throttle cable clasp (Fig. 89). 8. If equipped with speed control, rotate throttle lever forward to the wide open position and slide speed control cable connector onto nail head. 9. Rotate throttle lever forward to the wide open position and slide kickdown cable connector onto nail head. 10. Install throttle cable cover. Tighten bolt to 5.6 Nm (50 in lb). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Automatic Transmission > Page 3299 Throttle Body: Service and Repair Manual Transmission Fig. 86 Throttle Cable Attachment to Throttle Body Fig. 87 Disconnecting Throttle Cable REMOVAL 1. Remove throttle cable cover. 2. Remove throttle cable from the throttle body cam (Fig. 86) and (Fig. 87). 3. Compress the retaining tabs on the cable and slide cable out of bracket (Fig. 87). 4. If equipped with speed control, remove speed control cable from throttle lever by sliding clasp out hole used for throttle cable. 5. Remove 2 screws holding cable mounting bracket and support bracket. 6. Remove TPS connector. 7. Remove Idle Air Control motor connector. 8. Remove the EVAP purge hose. 9. Remove throttle body mounting bolts. Remove throttle body. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Automatic Transmission > Page 3300 Fig. 92 Re-Usable Throttle Body Gasket 10. The rubber 0-ring gasket on the intake manifold is reusable. - Wipe the 0-ring clean before installing throttle body (Fig. 92). INSTALLATION 1. Install throttle body on intake manifold. Tighten mounting bolts to 23 Nm (200 in lb). 2. Attach cable mounting bracket and support bracket with 2 screws. 3. Connect the electrical connection to the throttle body. 4. Connect the EVAP purge hose to the throttle body 5. Install cable housing(s) retainer tabs into bracket. 6. If equipped with speed control. rotate the throttle lever forward to the wide open position and install speed control cable clasp (Fig. 87). 7. Rotate throttle lever to wide open position and install throttle cable clasp (Fig. 87). 8. Install throttle cable cover. Tighten bolt to 5.6 Nm (50 in lb). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Automatic Transmission Throttle Cable/Linkage: Service and Repair Automatic Transmission Fig. 5 Throttle Body Cables Attachment To Throttle Body Fig. 6 Disconnecting Throttle Cable REMOVAL 1. Working from the engine compartment, remove throttle cable from throttle body cam (Figs. 5 and 6). 2. Compress the retaining tabs on the cable and slide cable out of bracket (Fig. 6). Fig. 2 Accelerator Pedal And Throttle Cable -- Rear View Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Automatic Transmission > Page 3305 Fig. 2 Accelerator Pedal And Throttle Cable -- Rear View 3. From inside the vehicle, hold the throttle pedal up and remove the cable retainer and cable from upper end of pedal shaft (Fig. 1 and Fig. 2). 4. Remove retainer clip from throttle cable and grommet at the dash panel (Fig. 2). 5. From the engine compartment, pull the throttle cable out of the dash panel grommet. The grommet should remain in the dash panel. INSTALLATION 1. From the engine compartment, push the housing end fitting into the dash panel grommet. 2. Install cable housing (throttle body end) into the cable mounting bracket on the engine. 3. From inside the vehicle, hold up pedal and feed throttle cable core wire through hole in upper end of the pedal shaft. Install cable retainer (Fig. 2). 4. Install cable retainer clip (Fig. 2). 5. From the engine compartment, rotate the throttle lever forward to the wide open position and install cable clasp (Fig. 6). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Automatic Transmission > Page 3306 Throttle Cable/Linkage: Service and Repair Manual Transmission Fig. 3 Throttle Cable Attachment To Throttle Body Fig. 4 Disconnecting Throttle Cable REMOVAL 1. Working from the engine compartment, remove the throttle cable from the throttle body lever (Figs. 3 and 4). 2. Compress the retaining tabs on the cable and slide cable out of bracket (Fig. 4). Fig. 1 Accelerator Pedal And Throttle Cable -- Front View Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Automatic Transmission > Page 3307 Fig. 2 Accelerator Pedal And Throttle Cable -- Rear View 3. From inside the vehicle, hold the accelerator pedal up and remove the cable retainer and cable from upper end of pedal shaft (Figs. 1 and 2). 4. Remove retainer clip from throttle cable and grommet at the dash panel (Fig. 2). 5. From the engine compartment, pull the throttle cable out of the dash panel grommet. The grommet should remain in the dash panel. INSTALLATION 1. From the engine compartment, push the housing end fitting into the dash panel grommet. 2. Install cable housing (throttle body end) into the cable mounting bracket on the engine. 3. From inside the vehicle, hold up pedal and feed throttle cable core wire through hole in upper end of the pedal shaft. Install cable retainer (Fig. 2). 4. Install cable retainer clip (Fig. 2). 5. From the engine compartment, rotate the throttle lever forward to the wide open position and install cable clasp (Fig. 4). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: Customer Interest Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 3316 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set Throttle Position Sensor: All Technical Service Bulletins Throttle Body/TPS - MIL ON/DTC MIL 24 Set NO: 18-04-96 GROUP: Vehicle Performance DATE: Feb. 16, 1996 SUBJECT: Erratic Idle And MIL Illuminated MODELS: 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus 1995 - 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES EQUIPPED WITH 2.01 ENGINES BUILT PRIOR TO NOVEMBER 1, 1995 (MDH 11-01-XX). SYMPTOM/CONDITION: Loss of performance and/or Malfunction Indicator Light (MIL) illuminated (indicating failed TPS) and/or erratic idle. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRBII) and the appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) other than DTC" MIL 24" "Failed Throttle Position Sensor" are present, record them on the repair order for future reference and repair as necessary. Check the throttle body part number against the throttle body part numbers given below. The throttle body part number can be found on the side of the throttle body by the vacuum purge nipple. Figure 1 ^ Throttle Body Part Numbers: 4669540 4669541 4663077 4669167 4669246 4669245 5277745 5277765 4669032 4669313 ^ If the vehicle DOES have one of the throttle bodies listed above, the throttle body assembly should be replaced. These throttle bodies were built without an 0-ring seal that prevents moisture contamination. The superseded part number for the replacement throttle body can be found by entering the part number found on the existing throttle body into the parts ordering system. ^ If the vehicle DOES NOT have one of the throttle bodies shown in the list above, refer to the repair procedure below for throttle position sensor replacement. NOTE: IF THE THROTTLE BODY IS TO BE REPLACED, IT IS NOT NECESSARY TO REPLACE THE THROTTLE POSITION SENSOR. THE NEW THROTTLE BODY WILL COME EQUIPPED WITH THE UPDATED TPS AND REQUIRED 0-RING. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 180496 > Feb > 96 > Throttle Body/TPS - MIL ON/DTC MIL 24 Set > Page 3322 PARTS REQUIRED: AR 4874430 Throttle Position Sensor, SOHC (PL, JA) AR 4874431 Throttle Position Sensor, DOHC (PL, JA) AR 4874430 Throttle Position Sensor, SOHC or DOHC (FJ) REPAIR PROCEDURE: This bulletin involves the replacement of the throttle position sensor and 0-ring, or the replacement of the throttle body. THROTTLE POSITION SENSOR REPLACEMENT: 1. Remove throttle position sensor from the throttle body by removing the two attaching screws. The attaching screws should be discarded. Replacement screws will be provided with the new throttle position sensor. 2. Remove the 0-ring from the throttle body casting and discard. 3. Lubricate the new 0-ring provided with the new throttle position sensor. Apply one to three drops of a light grade of vegetable oil and allow excess to drain off. CAUTION: DO NOT USE ENGINE OIL, IT WILL NOT PROPERLY LUBRICATE THE 0-RING. 4. Install the 0-ring into the groove in the throttle body. CAUTION: DO NOT INSTALL THE 0-RING ONTO THE NOSE PILOT OF THE THROTTLE POSITION SENSOR OR DAMAGE MAY OCCUR. 5. Install the throttle position sensor and attachment screws as outlined in the appropriate service manual under group 14, throttle position sensor installation. THROTTLE BODY REPLACEMENT: 1. To replace the throttle body refer to the appropriate service manual in group 14, throttle body removal and installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No.: 14-30-02-94 0.4 Hrs. Throttle Body - Replace (JA, FJ) 14-30-02-95 0.5 Hrs. Throttle Body - Replace (PL) 08-14-10-97 0.3 Hrs. Sensor, Throttle Position - Replace (JA, FJ Sebring) 08-14-10-98 0.6 Hrs. Sensor, Throttle Position - Replace (PL) 08-14-10-99 0.2 Hrs. Sensor, Throttle Position - Replace (FJ Talon) FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications As the throttle plate rotates, the TP sensor provides a variable 0 to 5 volt signal to PCM cavity 10. Sensor Resistance .............................................................................................................................. ........................................................ 3.5k to 6.5k ohms Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3325 Throttle Position Sensor: Mechanical Specifications Throttle Position Sensor Torque = 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3326 Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3327 Throttle Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation Throttle Position Sensor: Description and Operation Throttle Position Sensor Operation Fig. 16 Throttle Position Sensor And Idle Air Control Motor -- Typical PURPOSE Along with inputs from other sensors, the PCM uses the Throttle Position Sensor (TPS) input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. OPERATION The TPS mounts to the throttle body and connects to the throttle blade shaft. The TPS is a variable resistor that provides the PCM with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts DC to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies: At minimum throttle opening (idle) -- from 0.38 to 1.03 volts. - AT Wide open throttle -- 3.1 to 4.0 volts. The throttle position sensor mounts to the side of the throttle body (Fig. 16). CIRCUIT OPERATION From the Powertrain Control Module (PCM) circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity 61 of the PCM connector. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity 35 of the PCM connector. The PCM provides ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 3330 Throttle Position Sensor: Description and Operation Related Trouble Codes & Set Conditions Throttle Position Sensor Voltage High Name of Code: Throttle Position Sensor Voltage High When Monitored: With the ignition on. Set Condition: TP sensor voltage at PCM cavity 35 goes above 4.5 volts for 0.704 seconds. Theory of Operation: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 35. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. Possible Causes: - Sensor signal circuit open - Throttle position sensor failure - Sensor ground circuit open - PCM failure - Connector terminals - Connector wires Throttle Position Sensor Voltage Low NAME OF CODE: Throttle Position Sensor Voltage Low WHEN MONITORED: With the ignition ON. SET CONDITION: The Throttle Position (TP) sensor voltage at Powertrain Control Module (PCM) cavity 35 goes below 0.2 volt for 0.704 seconds, or MPH is above 20, RPM is above 1500, and vacuum is below 2" with TP sensor voltage less than 0.5 volt for 0.704 seconds. THEORY OF OPERATION: The throttle position sensor contains a potentiometer that is operated by the throttle blade shaft. As the throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM cavity 10. The voltage is directly proportional to throttle angle. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Sensor signal circuit shorted to ground - Throttle position sensor failure - Loss of 5-volt supply TPS Voltage Does Not Agree With MAP Name of Code: TPS Voltage Does Not Agree with MAP When Monitored: With the engine running and no MAP sensor or TP sensor trouble codes. Set Condition: The powertrain control module (PCM) performs two separate tests on the TP sensor: the high voltage test and the low voltage test. The high voltage test is performed when the engine speed is very low and manifold vacuum is very high; these conditions indicate that the throttle plate must be nearly closed, in which case the TP sensor signal voltage output must be low. The low voltage test is performed when the engine speed is above 25 mph and manifold vacuum is low; these conditions indicate that the throttle plate is open, in which case the TP sensor signal must be high. If the proper TP sensor voltage is not present when the two conditions are met, the code will set after 4 continuous seconds. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Throttle Position Sensor Operation > Page 3331 Theory of Operation: The TP sensor contains a potentiometer that is operated by the throttle blade shaft. As a throttle plate rotates, the TP sensor provides a variable 0 to 5-volt signal to PCM. The voltage is directly proportional to throttle angle. When the throttle plate is at rest, the voltage is low. When the throttle is fully open, the voltage is high. With this signal, the PCM can determine precise throttle position under all operating conditions. The TP sensor receives a 5-volt supply from the PCM. The sensor ground is provided by the PCM. Possible Causes: - Failed powertrain control module - Connector wires - TP sensor failure - Vehicle speed - Mechanical failure - MAP sensor - Connector terminals Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3334 Throttle Position Sensor: Testing and Inspection Component Testing The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor around terminal. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately 0.38 volts to 1.03 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.0 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3335 Throttle Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3336 Throttle Position Sensor: Adjustments The TPS was not designed to be adjusted. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3337 Throttle Position Sensor: Service and Repair Fig. 22 Throttle Position Sensor And Idle Air Control Motor NOTE: The throttle position sensor attaches to the side of the throttle body (Fig. 22). REMOVAL 1. Disconnect EVAP purge hose from throttle body. 2. Disconnect electrical connector from idle air control motor and throttle position sensor. 3. Remove throttle body Refer to procedure. 4. Remove throttle position sensor mounting screws. 5. Remove throttle position sensor. Fig. 23 Throttle Position Sensor Installation INSTALLATION 1. The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 23). The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position. - If it is difficult to rotate the TPS into position, install the sensor with the throttle shaft on the other side of the tabs in the socket. 2. Tighten mounting screws to 2 Nm (20 in lb) torque. - After installing the TPS, the throttle plate should be closed. - If the throttle plate is open, install the sensor on the other side of the tabs in the socket. 3. Install throttle body Refer to procedure. 4. Attach electrical connectors to idle air control motor and throttle position sensor. 5. Install EVAP purge hose to throttle body nipple. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications 1995 - 1996 2.0L, 2.4L Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Cable Routing and Firing Order Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3352 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3353 Camshaft Position Sensor: Locations Camshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3354 Camshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Operation Fig.9 Camshaft Position Sensor-DOHC PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity OPERATION Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 3357 The camshaft position sensor attaches to the rear of the cylinder head (Fig. 9). 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 (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. The sensor also acts as a thrust plate to control camshaft endplay. CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the camshaft position sensor The K7 circuit connects to cavity 44 of the PCM connector. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 33 of the PCM connector. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 3358 Camshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP Trouble Code Name of Code: Intermittent Loss of CMP or CKP When Monitored: During engine running. Set Condition: When the expected cam signal level disagrees with the actual cam signal level. Theory of Operation: After the engine has been started, the powertrain control module maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. Possible INTERMITTENT Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 3359 Camshaft Position Sensor: Description and Operation No Cam Signal at PCM Trouble Code Name of Code: No Cam Signal at PCM When Monitored: During engine cranking, after a number of crank position sensor signals have been detected. Set Condition: Signals are not received from the camshaft position sensor when signals are received from the crankshaft position sensor Theory of Operation: The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. The PCM supplies 8 volts and a sensor ground to the CMP sensor. The camshaft position sensor signal circuit has a 5 volt pull-up from the PCM. The sensor signal is created by a rotating target magnet attached to the rear of the camshaft when the north pole of the magnet passes under the sensor, the signal remains at 5 volts. When the south pole passes under the sensor, the signal drops to 0.3 volt. Possible Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and target magnet - Damaged target magnet - Failed sensor - Failed PCM - Broken timing belt - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3362 Camshaft Position Sensor: Testing and Inspection Failure to Start Test This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3363 Camshaft Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Sensor Replacement Fig. 8 Camshaft Position Sensor Location Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head (Fig. 8). REMOVAL 1. Remove filtered air tube from the throttle body and air cleaner housing. 2. Disconnect electrical connector from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.35 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft (Fig. 35). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 3366 Fig.36 Target Magnet Installation NOTE: The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft (Fig. 36). INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install filtered air tube. Tighten clamps to 3 Nm ±1 (25 in lb ±5) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 3367 Camshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3372 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position Sensor Bolts ........................................................................................................ .......................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3373 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3374 Crankshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor-PCM Input Fig. 15 Crankshaft Position Sensor Fig. 14 Timing Reference Notches Fig.6 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60° signature notch (Fig. 14). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 3377 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. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69° before top dead center (BTDC). - The second notch represents 49° BTDC. - The third notch represents 29°. - The last notch in each set represents 9° before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM connector. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 3378 Crankshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP Trouble Code Name of Code: Intermittent Loss of CMP or CKP When Monitored: During engine running. Set Condition: When the expected cam signal level disagrees with the actual cam signal level. Theory of Operation: After the engine has been started, the powertrain control module maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. Possible INTERMITTENT Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 3379 Crankshaft Position Sensor: Description and Operation No Crank Reference Signal at PCM Trouble Code Name of Code: No Crank Reference Signal at PCM When Monitored: During engine cranking, with battery voltage less than 11.5 volts and manifold vacuum present. Set Condition: No signal from the crankshaft position (CKP) sensor during engine cranking or there is a camshaft position sensor signal without a CKP sensor signal. Theory of Operation: The crankshaft position sensor is a hall-effect type sensor used to detect crankshaft speed and position. The PCM supplies 8 volts and a sensor ground to the CKP sensor. The crankshaft position sensor signal circuit has a 5-volt pull-up from the PCM. The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. When there isn't a notch under the sensor, the signal drops to 0.3 volt. Possible Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and crankshaft pulse ring - Damaged crankshaft pulse ring - Failed sensor - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 3382 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 3383 Crankshaft Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig. 12 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 12). 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Crankshaft Position Sensor Bolts torque ....................................................................................................................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 3386 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum Cables #1 & #4 3,050 Ohms 4,250 Ohms Cables #2 & #3 2,300 Ohms 3,300 Ohms Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 3390 Ignition Cable: Description and Operation NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Plastic clips in various locations protect the cables from damage. When the cables are replaced the clips must be used to prevent damage to the cables. The #1 cable must be routed under the PCV hose and clipped to the #2 cable. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Ignition Cable: Initial Inspection and Diagnostic Overview Fig. 3 Spark Plug Cables NOTE: Resistance cables are identified by the words Electronic Suppression. Spark plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the coil pack to individual spark plugs at each cylinder. - The resistor type, nonmetallic spark plug cables provide suppression of radio frequency emissions from the ignition system. CHECKING Check for brittle or cracked insulation. Check the spark plug cable connections for good contact at the coil and spark plugs. Terminals should be fully seated. - The nipples and spark plug covers should be in good condition. - Nipples should fit tightly on the coil. - Spark plug boot should completely cover the spark plug hole in the cylinder head cover. Install the boot until the terminal snaps over the spark plug. A snap must be felt to ensure the spark plug cable terminal engaged the spark plug. - Loose cable connections will corrode, increase resistance and permit water to enter the towers. - These conditions can cause ignition malfunction. Be sure that the plastic clip on PCV hose is positioned so that cable clip is beneath hose, and that #1 cable is snapped into this clip to protect it from metal PCV clamp. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3393 Ignition Cable: Component Tests and General Diagnostics Testing For Open Circuits, High Resistance and Loose Terminals Use an ohmmeter to check cables for opens, loose terminals or high resistance as follows: 1. Remove cable from spark plug. 2. Remove cable from the coil tower. 3. Connect the ohmmeter between the spark plug end terminal and the coil end terminal. - Make sure ohmmeter probes are in good contact. - Resistance should be within tolerance shown in the cable resistance chart. - If resistance is not within tolerance, replace cable assembly. Test all spark plug cables in the same manner. - If no problems are found, SEE Ignition System/System Diagnosis/Testing For Spark At Coil. SECONDARY IGNITION CABLE RESISTANCE Minimum Maximum Cables #1 & #4 3,050 Ohms 4,250 Ohms Cables #2 & #3 2,300 Ohms 3,300 Ohms Testing For Punctures and Cracks When testing cables for punctures and cracks with an oscilloscope and an inductive voltage probe, follow the instructions of the equipment manufacturers. CAUTION: Do not leave any one spark plug cable disconnected for more than 30 seconds during test or possible heat damage to catalytic converter will occur. If an oscilloscope and inductive probe are not available, cables can be tested as follows: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. WARNING: The ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. 2. With the engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). - If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. - Replace cracked, leaking or faulty cables. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair > Cleaning Ignition Cable: Service and Repair Cleaning Clean high tension cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair > Cleaning > Page 3396 Ignition Cable: Service and Repair Replacement Fig. 3 Spark Plug Cables NOTE: The cables insulate the spark plugs and cover the top of the spark plug tube (Fig. 3). CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. REMOVAL 1. Remove spark plug cable from coil first. Lightly grasp the top of the cable. 2. Rotate the insulator 1/2 turn and pull straight up in a steady motion. 3. To replace the cables, disconnect the cable from the ignition coil. INSTALLATION Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube.Then connect the other end to coil pack. Be sure that the plastic clip on PCV hose is positioned so that cable clip is beneath hose, and that #1 cable is snapped into this clip to protect it from metal PCV clamp. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications Ignition Coil: Electrical Specifications Coil Resistance Primary @ 21-27°C (70-80°F) ........................................................................................................................................................ 0.45 to 0.65 ohms Secondary @ 21-27°C (70-80°F) .............................................................................................................................................. 7,000 to 15,800 ohms Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications > Page 3401 Ignition Coil: Mechanical Specifications Ignition Coil to Cylinder Head Torque ...................................................................................................................................................... 22 Nm (200 in lb) Ignition Coil Bracket Nuts .................................................................................................................... ................................................... 22 Nm (200 in lbs) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3402 Fig.30 Electronic Ignition Coil Pack Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions Ignition Coil: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3405 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3406 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3407 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3408 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3409 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3410 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3411 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3412 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3413 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3414 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3415 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3416 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3417 Ignition Coil: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3418 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3419 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3420 Coil Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 3421 Cable Routing and Firing Order Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3422 Ignition Coil: Description and Operation Fig.4 Ignition Coil Pack WARNING: The direct ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. OPERATION The coil pack consists of 2 coils molded together The coil pack is mounted on the valve cover (Fig. 4). High tension leads route to each cylinder from the coil. The coil fires two spark plugs every power stroke. One plug is the cylinder under compression, the other cylinder fires on the exhaust stroke. Coil number one fires cylinder 1 and 4. Coil number two fires cylinders 2 and 3. The PCM determines which of the coils to charge and fire at the correct time. Fig.5 Power Distribution Center (PDC) The Auto Shutdown (ASD) relay provides battery voltage to the ignition coil. The PCM provides a ground contact (circuit) for energizing the coil. When the PCM breaks the contact, the energy in the coil primary transfers to the secondary causing the spark. The PCM will de-energize the ASD relay if it does not receive the crankshaft position sensor and camshaft position sensor inputs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3423 Coil Polarity CIRCUIT OPERATION Circuit A14 is a bus bar in the Power Distribution Center (PDC), and connects to battery voltage. The contact side of the Automatic Shut Down ( ASD) relay connects circuit A14 and circuit A142. A 20 Amp fuse in the PDC protects circuits A14 and A142. Circuit A14 also supplies voltage to the coil side of the ASD relay The Powertrain Control Module (PCM) controls the ground path circuit for the coil side of the ASD relay on circuit K51. Circuit K51 connects to cavity 67 of the PCM connector. Circuit A142 supplies voltage for the ignition coil pack. The coil pack consists of two individual coils molded together. The PCM controls the ground circuit of each coil. Circuit K19 is the ground circuit for the ignition coil that fires spark plugs # 1 and # 4. Circuit K19 connects to cavity 2 of the PCM. - Circuit K17 is the ground circuit for the ignition coil that fires spark plugs #2 and # 3. Circuit K17 connects to cavity 3 of the PCM. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Helpful Information Ignition Coil: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, ASD relay, generator, upstream heated oxygen sensor and downstream heated oxygen sensor. The PCM controls the ground circuit for each of the components powered by circuit A142. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Helpful Information > Page 3426 Ignition Coil: Testing and Inspection Ignition Coil Test Fig.18 Terminal Identification NOTE: Coil one fires cylinders 1 and 4, coil two fires cylinders 2 and 3. Each coil tower is labeled with the number of the corresponding cylinder. 1. Remove the ignition cables and measure the resistance of the cables. Resistance must be between ranges shown. Replace any cable not within tolerance. Secondary Ignition Cable Resistance Minimum Maximum Cables #1 & #4 3,050 Ohms 4,250 Ohms Cables #2 & #3 2,300 Ohms 3,300 Ohms 2. Disconnect the electrical connector from the coil pack. 3. Measure the primary resistance of each coil. At the coil, connect an ohmmeter between the B+ pin and the pin corresponding to the cylinders in question (Fig. 18). Resistance on the primary side of each coil should be 0.45 - 0.65 ohm. Replace the coil if resistance is not within tolerance. 4. Remove ignition cables from the secondary towers of the coil. Measure the secondary resistance of the coil between the towers of each individual coil (Fig. 19). Secondary resistance should be 11,000 to 14,000 ohms. Replace the coil if resistance is not within tolerance. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Helpful Information > Page 3427 Ignition Coil: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Page 3428 Ignition Coil: Service and Repair Fig.30 Electronic Ignition Coil Pack NOTE: The electronic ignition coil pack attaches to a bracket mounted on top of the cylinder head cover (Fig. 30). REMOVAL 1. Disconnect electrical connector from coil pack. 2. Remove coil pack mounting nuts. 3. Remove coil. 4. Install coil pack on valve cover. 5. Transfer spark plug cables to new coil pack. - The coil pack towers are numbered with the cylinder identification. NOTE: Be sure the ignition cables snap onto the towers. Ignition Coil to Cylinder Head Torque ..................................................................................................................................................... 22 Nm (200 in lb) Ignition Coil Bracket Nuts .................................................................................................................... ................................................... 22 Nm (200 in lbs) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 3432 Knock Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 3433 Knock Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation Knock Sensor: Description and Operation Knock Sensor Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 24 of the PCM connector. The PCM provides ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation > Page 3436 Knock Sensor: Description and Operation Knock Sensor Circuit Trouble Code Name of Code: Knock Sensor Circuit When Monitored: With the ignition on and the engine running. Set Condition: The knock sensor circuit voltage falls below a minimum value at idle or deceleration, The minimum value is from a look-up table internal to the PCM and is based on engine rpm. The trouble code also sets if the sensor output is above 5.0 volts. Theory of Operation: The knock sensor is mounted on the cylinder block below the intake manifold. The knock sensor is comprised of thin piezo-electric ceramic discs bonded to a metal diaphragm. When engine knock occurs, the diaphragm vibrates along with the piezoelectric discs, producing an electrical signal. The signal is used by the PCM to adjust ignition timing to eliminate the knock condition. Possible Causes: - Sensor signal open - Sensor internally open - PCM failure - Sensor signal circuit shorted to ground - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Testing and Inspection > Helpful Information Knock Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3439 Knock Sensor: Testing and Inspection Component Testing The knock sensor can be tested with a digital voltmeter. Sensor output should be between 80 mV and 4 volts with the engine running between 576 and 2,208 rpm. If the output falls outside of this range a DTC will be set. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3440 Knock Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Testing and Inspection > Page 3441 Knock Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Cam Position Sensor - Oil Seepage Diagnosis Camshaft Position Sensor: Technical Service Bulletins Cam Position Sensor - Oil Seepage Diagnosis NO: 09-07-98 GROUP: Engine DATE: Dec. 11, 1998 SUBJECT: Oil Seepage At Cam Position Sensor/Misinterpreted Head Gasket Leak THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-02-94, DATED MAR. 18, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-95054). THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. MODELS: 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible (Export Market) 1995 - 1999 (PL) Neon 1997 - 1999 (GS) Caravan/Voyager (Export Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO MODELS WITH A 2.0L SOHC/DOHC OR A 2.4L ENGINE. DISCUSSION: Whenever performing oil leak diagnosis on one of these models carefully inspect the cam sensor area to determine if the leak originates from the seal or from other sources. A leak in this area can be mis-interpreted as a leaking head gasket. Additionally, whenever a head gasket is replaced, the cam seal should always be replaced to prevent the possibility of the vehicle returning with oil seepage. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications The sensor signal is created by a rotating target magnet attached to the rear of the camshaft. When the north pole of the magnet passes under the sensor, the signal remains at 5 volts. - When the the south pole passes under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3449 Camshaft Position Sensor: Mechanical Specifications Camshaft Position Sensor Torque = 9 Nm (80 in lb) Camshaft Position Sensor Target Magnet Torque = 3 Nm (30 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3450 Camshaft Position Sensor: Locations Camshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3451 Camshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation Camshaft Position Sensor: Description and Operation Camshaft Position Sensor Operation Fig.9 Camshaft Position Sensor-DOHC PURPOSE The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Fig. 6 Target Magnet Fig. 7 Target Magnet Polarity OPERATION Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 3454 The camshaft position sensor attaches to the rear of the cylinder head (Fig. 9). 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 (Fig. 6). As the target magnet rotates, the camshaft position sensor senses the change in polarity (Fig. 7). The sensor output switch switches from high (5.0 volts) to low (0.30 volts) as the target magnet rotates. When the north pole of the target magnet passes under the sensor, the output switches high. - The sensor output switches low when the south pole of the target magnet passes underneath. Fig. 24 Square Wave Pattern In Crankshaft Degrees Square Wave Output The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (less than 0.5 volts). By connecting an oscilloscope to the sensor output circuit, technicians can view the square wave pattern produced by the voltage swing (Fig. 24). If the camshaft position sensor and crankshaft position sensor don't produce a square wave pattern, check the 8-volt supply circuit that feeds both sensors. The sensor also acts as a thrust plate to control camshaft endplay. CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the camshaft position sensor The K7 circuit connects to cavity 44 of the PCM connector. Circuit K44 from the sensor provides an input signal to the PCM. The K44 circuit connects to cavity 33 of the PCM connector. The PCM provides ground for the camshaft position sensor signal (circuit K44) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 3455 Camshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP Trouble Code Name of Code: Intermittent Loss of CMP or CKP When Monitored: During engine running. Set Condition: When the expected cam signal level disagrees with the actual cam signal level. Theory of Operation: After the engine has been started, the powertrain control module maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. Possible INTERMITTENT Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor Operation > Page 3456 Camshaft Position Sensor: Description and Operation No Cam Signal at PCM Trouble Code Name of Code: No Cam Signal at PCM When Monitored: During engine cranking, after a number of crank position sensor signals have been detected. Set Condition: Signals are not received from the camshaft position sensor when signals are received from the crankshaft position sensor Theory of Operation: The camshaft position (CMP) sensor is a hall-effect type sensor used to detect the camshaft's position. The PCM supplies 8 volts and a sensor ground to the CMP sensor. The camshaft position sensor signal circuit has a 5 volt pull-up from the PCM. The sensor signal is created by a rotating target magnet attached to the rear of the camshaft when the north pole of the magnet passes under the sensor, the signal remains at 5 volts. When the south pole passes under the sensor, the signal drops to 0.3 volt. Possible Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and target magnet - Damaged target magnet - Failed sensor - Failed PCM - Broken timing belt - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information Camshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Crankshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3459 Camshaft Position Sensor: Testing and Inspection Failure to Start Test This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3460 Camshaft Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement Camshaft Position Sensor: Service and Repair Camshaft Sensor Replacement Fig. 8 Camshaft Position Sensor Location Fig. 9 Target Magnet Removal/Installation NOTE: The camshaft position sensor is mounted to the rear of the cylinder head (Fig. 8). REMOVAL 1. Remove filtered air tube from the throttle body and air cleaner housing. 2. Disconnect electrical connector from camshaft position sensor. 3. Remove camshaft position sensor mounting screws. Remove sensor. Fig.35 Target Magnet Removal/Installation 4. Loosen screw attaching target magnet to rear of camshaft (Fig. 35). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 3463 Fig.36 Target Magnet Installation NOTE: The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft (Fig. 36). INSTALLATION 1. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in lb) torque. 2. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (80 in lb) torque. 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install filtered air tube. Tighten clamps to 3 Nm ±1 (25 in lb ±5) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Sensor Replacement > Page 3464 Camshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. - When there isn't a notch under the sensor, the signal drops to 0.3 volt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3469 Crankshaft Position Sensor: Mechanical Specifications Crankshaft Position Sensor Bolts ........................................................................................................ .......................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3470 Crankshaft Position Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3471 Crankshaft Position Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor-PCM Input Fig. 15 Crankshaft Position Sensor Fig. 14 Timing Reference Notches Fig.6 Timing Reference Notches PURPOSE The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). OPERATION The second crankshaft counterweight has machined into it two sets of four timing reference notches including a 60° signature notch (Fig. 14). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 3474 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. By counting the pulses and referencing the pulse from the 60° signature notch, the PCM calculates crankshaft angle (position). In each group of timing reference notches: The first notch represents 69° before top dead center (BTDC). - The second notch represents 49° BTDC. - The third notch represents 29°. - The last notch in each set represents 9° before top dead center BTDC. The timing reference notches are machined at 20° increments. From the voltage pulse-width the PCM tells the difference between the timing reference notches and the 60° signature notch. The 60° signature notch produces a longer pulse-width than the smaller timing reference notches. - If the camshaft position sensor input switches from high to low when the 60° signature notch passes under the crankshaft position sensor, the PCM knows cylinder number one is the next cylinder at TDC. Oscilloscope Display of Waveform If available, an oscilloscope can display the square wave patterns of each voltage pulse. From the frequency of the output voltage pulses, the PCM calculates engine speed. The width of the pulses represent the amount of time the output voltage stays high before switching back to low. - The period of time the sensor output voltage stays high before switching back to low is referred to as pulse-width. - The faster the engine is operating, the smaller the pulse-width on the oscilloscope. The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 15). CIRCUIT OPERATION Circuit K7 supplies 8 Volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit connects to cavity 44 of the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM connector. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 3475 Crankshaft Position Sensor: Description and Operation Intermittent Loss of CMP or CKP Trouble Code Name of Code: Intermittent Loss of CMP or CKP When Monitored: During engine running. Set Condition: When the expected cam signal level disagrees with the actual cam signal level. Theory of Operation: After the engine has been started, the powertrain control module maintains an expected camshaft port level value. At every 69 degree crank edge this value is toggled to reflect the expected change in the cam level. At every crank falling edge, this value is compared to the true camshaft port level. If there is a disagreement between the two values, then the trouble code is matured and set. At this time, the powertrain control module is forced back into a spark start mode and it attempts to synchronize the cam and crank signals. Possible INTERMITTENT Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the crankshaft sensor and crankshaft pulse ring - Excessive clearance between the camshaft sensor and the target magnet - Damaged target magnet - Damaged crankshaft pulse ring - Failed sensor - Failed PCM Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Crankshaft Position Sensor-PCM Input > Page 3476 Crankshaft Position Sensor: Description and Operation No Crank Reference Signal at PCM Trouble Code Name of Code: No Crank Reference Signal at PCM When Monitored: During engine cranking, with battery voltage less than 11.5 volts and manifold vacuum present. Set Condition: No signal from the crankshaft position (CKP) sensor during engine cranking or there is a camshaft position sensor signal without a CKP sensor signal. Theory of Operation: The crankshaft position sensor is a hall-effect type sensor used to detect crankshaft speed and position. The PCM supplies 8 volts and a sensor ground to the CKP sensor. The crankshaft position sensor signal circuit has a 5-volt pull-up from the PCM. The sensor signal is created by the notches in the crankshaft pulse ring passing under the sensor. When a notch is under the sensor, the signal remains at 5 volts. When there isn't a notch under the sensor, the signal drops to 0.3 volt. Possible Causes: - Open or shorted 8-volt supply circuit - Open sensor ground - Open or shorted signal circuit - Excessive clearance between the sensor and crankshaft pulse ring - Damaged crankshaft pulse ring - Failed sensor - Failed PCM - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test Crankshaft Position Sensor: Testing and Inspection Failure to Start Test This no-start test checks the camshaft position sensor and crankshaft position sensor. Use the DRB or scan tool to test the camshaft position sensor and the sensor circuits. Refer to Diagrams/Electrical for circuit information. The PCM supplies 8 volts to the camshaft position sensor and crankshaft position sensor through one circuit. If the 8-volt supply circuit shorts to ground, neither sensor will produce a signal (output voltage to the PCM). When the ignition key is turned and left in the On position, the PCM automatically energizes the auto shutdown (ASD) relay. However, the PCM de-energizes the relay within one second because it has not received a crankshaft position sensor signal indicating engine rotation. During cranking, the ASD relay will not energize until the PCM receives a camshaft position sensor signal. Secondly, the ASD relay remains energized only if the PCM senses a crankshaft position sensor signal immediately after detecting the camshaft position sensor signal. 1. Check battery voltage. Voltage should be approximately 12.66 volts or higher to perform failure to start test. 2. Disconnect the harness connector from the coil pack (Fig. 20). 3. Connect a test light to the B+ (battery voltage) terminal of the coil electrical connector and ground. The B+ wire for the DIS coil is the center terminal. Do not spread the terminal with the test light probe. 4. Turn the ignition key to the ON position.- The test light should flash ON and then OFF. Do not turn the Key to OFF position, leave it in the ON position. a. If the test light flashes momentarily, the PCM grounded the ASD relay. Proceed to step 5. b. If the test light did not flash, the ASD relay did not energize. The cause is either the relay or one of the relay circuits. Use the DRB or scan tool to test the ASD relay and circuits. Check for codes and follow procedures. SEE Computers and Control Systems/Testing and Inspection/ Diagnostic Charts. Refer to Diagrams/Electrical for circuit information. 5. Crank the engine. (If the key was placed in the OFF position after step 4, place the key in the ON position before cranking. Wait for the test light to flash once, then crank the engine.) 6. If the test light momentarily flashes during cranking, the PCM is not receiving a crankshaft position sensor signal. 7. If the test light did not flash during cranking, unplug the crankshaft position sensor connector. Turn the ignition key to the off position. Turn the key to the ON position, wait for the test light to momentarily flash once, then crank the engine. If the test light momentarily flashes, the crankshaft position sensor is shorted and must be replaced. If the light did not flash, the cause of the no-start is in either the crankshaft position sensor/ camshaft position sensor 8 volt supply circuit, or the camshaft position sensor output or ground circuits. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 3479 Crankshaft Position Sensor: Testing and Inspection Helpful Information Circuit K7 splices to supply 8 Volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Battery temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Testing and Inspection > Failure to Start Test > Page 3480 Crankshaft Position Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Fig. 12 Crankshaft Position Sensor NOTE: The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig. 12). 1. Disconnect electrical connector from crankshaft position sensor. 2. Remove sensor mounting screw. Remove sensor. 3. Reverse procedure for installation. Crankshaft Position Sensor Bolts torque ....................................................................................................................................................... 9 Nm (80 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 3483 Crankshaft Position Sensor: Service and Repair Camshaft/Crankshaft Timing Relearn The content of this article reflects changes called for in TSB 26-01-98. Camshaft and Crankshaft Timing Relearn 1. Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of the instrument panel; near the steering column. 2. Turn the ignition switch on and access the "miscellaneous" screen (or appropriate screen on generic scan tool). 3. Select "re-learn cam/crank" option and follow directions on DRB screen. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation Fig.16 Ignition Lock Cylinder Detents The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detents: Accessory - Off (lock) - Unlock - On/Run - Start Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 3488 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Detentes The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detentes: Accessory - Off (lock) - Unlock - On/Run - Start REMOVAL 1. Disconnect negative cable from battery. 2. Place key cylinder in RUN position. - Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. - Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. - To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. - Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Connect negative cable to battery Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Torque = 10 Nm (7 ft lb or 90 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3492 Knock Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3493 Knock Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation Knock Sensor: Description and Operation Knock Sensor Operation Fig. 11 Knock Sensor PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM. As the intensity of the engine knock vibration increases, the knock sensor output voltage also increases. The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 11). CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. CIRCUIT OPERATION The knock sensor provides an input to the Powertrain Control Module (PCM) on circuit K42. Circuit K42 connects to cavity 24 of the PCM connector. The PCM provides ground for the knock sensor signal (circuit K42) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Operation > Page 3496 Knock Sensor: Description and Operation Knock Sensor Circuit Trouble Code Name of Code: Knock Sensor Circuit When Monitored: With the ignition on and the engine running. Set Condition: The knock sensor circuit voltage falls below a minimum value at idle or deceleration, The minimum value is from a look-up table internal to the PCM and is based on engine rpm. The trouble code also sets if the sensor output is above 5.0 volts. Theory of Operation: The knock sensor is mounted on the cylinder block below the intake manifold. The knock sensor is comprised of thin piezo-electric ceramic discs bonded to a metal diaphragm. When engine knock occurs, the diaphragm vibrates along with the piezoelectric discs, producing an electrical signal. The signal is used by the PCM to adjust ignition timing to eliminate the knock condition. Possible Causes: - Sensor signal open - Sensor internally open - PCM failure - Sensor signal circuit shorted to ground - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Helpful Information Knock Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Battery temperature sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3499 Knock Sensor: Testing and Inspection Component Testing The knock sensor can be tested with a digital voltmeter. Sensor output should be between 80 mV and 4 volts with the engine running between 576 and 2,208 rpm. If the output falls outside of this range a DTC will be set. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3500 Knock Sensor: Testing and Inspection Related Testing Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Page 3501 Knock Sensor: Service and Repair Fig. 16 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 16). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensors. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Spark Plugs - Intermittent Misfire Spark Plug: Technical Service Bulletins Spark Plugs - Intermittent Misfire NO: 18-10-97 GROUP: Vehicle Performance DATE: Feb. 28, 1997 SUBJECT: Intermittent Single Cylinder Misfire And/Or MIL Illuminated THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-15-96 REV. A DATED JULY 12, 1996 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1996 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-97010). ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE SPECIFIC ENGINE APPLICATIONS FOR FJ MODELS. MODELS: 1995 - 1996 (PL) Neon 1995 - 1996 (FJ) Avenger/Sebring/Talon 1995 - 1996 (JA) Cirrus/Stratus NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH 2.0L SOHC ENGINE (JA & PL), PRIOR TO JANUARY 2, 1996 (MDH 01-02-XX) AND WITH 2.0L DOHC ENGINE (PL) PRIOR TO APRIL 1, 1996 (MDH 04-01-XX) AND TO ALL 1995 & 1996 FJ **NATURALLY ASPIRATED** 2.0L VEHICLES. SYMPTOM/CONDITION: Intermittent single cylinder misfire as indicated by the Diagnostic Trouble Code (DTC) screen on the DRB III which cannot be readily reproduced. DIAGNOSIS: Follow the diagnostic steps in the 1996 Powertrain Diagnostic Manual for 2.0L/2.4L/2.5L/3.3L/3.5L Electronic Fuel Injection (Publication Number 81-699-95008), pages 417 to 419 (Test 107A). If the diagnostic repair procedure does not repair the problem, proceed to the repair procedure. PARTS REQUIRED: NOTE: IT IS IMPERATIVE THAT THE CHRYSLER PART NUMBER GIVEN BELOW BE REQUESTED WHEN ORDERING. ONLY THE CHRYSLER PART NUMBER WAS CHANGED, THE CHAMPION PART NUMBER DID NOT CHANGE. AR 5269897 Spark Plug, (PL & JA - SOHC & DOHC) AR 5269899 Spark Plug, (FJ- DOHC **Naturally Aspirated**) REPAIR PROCEDURE: This bulletin involves the replacement of the spark plug in the effected cylinder with a new spark plug. 1. Remove the spark plug cable. 2. Remove the spark plug and discard. 3. Install the new spark plug and torque to 28 Nm (20 ft. lbs.). 4. Install the spark plug cable. NOTE: THE FOLLOWING STEP IS REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Spark Plugs - Intermittent Misfire > Page 3506 5. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-17-03-91 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Specifications Spark Plug: Specifications Gap Specifications Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap .............................................................................................................................................. ............................................. 0.033 to 0.038 in Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Specifications > Page 3509 Spark Plug: Specifications Tightening Specifications Spark Plugs ......................................................................................................................................... ................................................ 28 Nm (20 ft lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Specifications > Page 3510 Spark Plug: Specifications Part Number and Thread Size Type - Champion RC9YC Thread size - 14mm (3/4 in) reach Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3511 Spark Plug: Application and ID Type - Champion RC9YC Thread size - 14mm (3/4 in) reach Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3512 Spark Plug: Description and Operation Resistor spark plugs are used in this engine. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. SEE Powertrain Management/Ignition System/Testing and Inspection/Procedures, for spark plug diagnosis. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3515 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3516 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3517 Spark Plug: Testing and Inspection Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3518 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator ELECTRODE INSULATOR Chipped Electrode Insulator Electrode Insulator A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation also can separate the insulator from the center electrode. A sudden rise in tip temperature or severe operating conditions are also possible causes. Spark plugs with chipped electrode insulators must be replaced. Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dry, Fluffy Black Deposits - Cold or Carbon Fouling COLD FOULING (CARBON FOULING) Normal Operation And Cold(Carbon) Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set may be caused by a Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3519 clogged air cleaner or poor ignition output. Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough operating temperature during short operating periods. Replace carbon fouled plugs with new spark plugs. Electrode Gap Bridging ELECTRODE GAP BRIDGING Electrode Gap Bridging Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned and reused. Heavy Colored Deposits DESCRIPTION: Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on the side facing the intake valve. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap, and reinstall .............................................................................................................................................................. .................................................................................... Normal Operating Conditions NORMAL OPERATING CONDITIONS Normal Operation And Cold(Carbon) Fouling The few deposits present will be probably light tan or slightly gray in color with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (0.001 in) per 1600 km (1000 miles) of operation for non Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3520 platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, have the electrodes filed and regapped, and then reinstalled. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum spark plugs. This would damage the platinum pads which would shorten spark plug life. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit. The rust color deposits can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits. Oil or Ash Encrusted OIL OR ASH ENCRUSTED Oil Or Ash Encrusted If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of spark plugs. Ash encrusted spark plugs can be cleaned and reused. Premature Electrode Wear - Preignition Damage PREIGNITION DAMAGE Preignition Damage Excessive combustion chamber temperature can cause preignition damage. First, the center electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Other possible causes include ignition timing over-advanced and incorrect spark plug heat range. Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3521 center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Determine if the spark plugs are the correct type, as specified on the VECI label, or if other operating conditions are causing engine overheating. Red, Brown, Yellow or White Deposits - Fuel Additives SCAVENGER DEPOSITS Scavenger Deposits Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a normal condition caused by chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed using standard procedures. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and reused. Shiny Yellow Glaze COMBUSTION DEPOSITS A shiny yellow glaze coating on the spark plug insulator is evidence of metallic by-products of fuel combustion, caused by chemical additives in certain fuels. Avoid sudden acceleration with wide open throttle after long periods of low speed driving. Spark plugs with combustion deposits can be cleaned and reused. Spark Plug Inspection ^ Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance Schedules. ^ Spark plugs that have low mileage may be cleaned and reused if not otherwise defective -- SEE Spark Plug Condition. After cleaning, file the center electrode flat with a small point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The spark plug gap is 0.033 to0.038 in. ^ Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Tighten spark plugs to 28 Nm (20 ft lb) torque. Wet Oily Deposits FUEL FOULING A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air and reinstall them in the engine. White or Gray - Burned or Blistered Insulator SPARK PLUG OVERHEATING Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3522 Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in. per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug overheating. Also check for lean air-fuel mixture. Check the torque value of the plugs to ensure good plug-engine seat contact. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 3523 Spark Plug: Adjustments Setting Spark Plug Electrode Gap Fig.2 Setting Spark Plug Electrode Gap Check the spark plug gap with a gap gauge. If the gap is not correct, adjust it by bending the ground -- center electrode. Refer to the Vehicle Emission Control Information (VECI) label, (under hood). If label is gone, or not readable, verify system and use the following specification. Plug Gap .............................................................................................................................................. ............................................. 0.033 to 0.038 in Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 3524 Spark Plug: Service and Repair CAUTION: Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. CAUTION: Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion. SPARK PLUG REMOVAL 1. Remove the spark plug using a quality socket with a rubber or foam insert. 2. Inspect the spark plug condition. SPARK PLUG CLEANING Spark plugs that have low mileage may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. CAUTION: Always tighten spark plugs to the specified torque. Over tightening can cause distortion and change the spark plug gap. SPARK PLUG INSTALLATION 1. To avoid cross threading, start the spark plug into the cylinder head by hand. 2. Tighten spark plugs to 28 Nm (20 ft lb) torque. 3. Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube. 4. Connect coil. SPARK PLUG TUBES The spark plugs tubes are pressed into the cylinder head. Sealant is applied to the end of the tube before installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Specifications Torque Converter Clutch Solenoid: Specifications The Torque Converter Clutch Solenoid ( TCCS ) if good should measure between 30 to 50 OHMS. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Component Locations Torque Converter Clutch Solenoid: Component Locations The Torque Converter Clutch Solenoid is located on the Valve Body. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Component Locations > Page 3533 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3534 Transmission Control Solenoid Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3535 Torque Converter Clutch Solenoid: Testing and Inspection The Transmission Torque Converter Clutch Solenoid is diagnosed using powertrain diagnostic trouble codes ( DTC ). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation CIRCUIT OPERATION The PRNDL lamp receives power on the E2 circuit from the 4 Amp fuse located in the fuse block in cavity 12. The fuse receives power from the headlamp switch. Circuit E2 also powers the ash receiver lamp. When the headlamp switch is moved to the PARK or ON position, current flows through the fuse to the PRNDL lamp. The ground for the lamp is supplied on the Z3 circuit, and terminates at the instrument panel left center support. This circuit is also spliced in with the ash receiver lamp, the ignition switch lamp, and the glove box lamp. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Throttle Position Sensor Mounting Screws 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3551 Transmission Connections Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 3554 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 3555 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 3556 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 3557 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 3558 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 3559 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 3560 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 3561 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 3562 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 3563 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 3564 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 3565 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 3566 Transmission Position Switch/Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 3567 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 3568 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 3569 Rear Lighting (Part 1 Of 3) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Park/Neutral Position Switch Operation Transmission Position Switch/Sensor: Description and Operation Park/Neutral Position Switch Operation Fig. 20 Park/Neutral Switch OPERATION The park/neutral position switch is located on the automatic transaxle housing Fig. 20. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. CIRCUIT OPERATION When CLOSED the Transmission Range Switch (TRS) provides an input to the Powertrain Control Module (PCM) on circuit T41. This circuit connects to cavity 76 of the PCM connector. The T41 circuit is spliced and provides a ground path for the engine starter relay, and the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Park/Neutral Position Switch Operation > Page 3572 Transmission Position Switch/Sensor: Description and Operation Park/Neutral Switch Failure Trouble Code Name of Code: Park/Neutral Switch Failure (Sense Circuit) When Monitored: With the transmission in Park, Neutral, or Drive and not in limp-in mode. Set Condition: This code is set if the PCM detects an incorrect Park/Neutral switch state for a given mode of vehicle operation. Theory of Operation: The Transmission range Sensor (Park/Neutral position switch on 3 speed auto and all manual trans) is used to communicate whether or not the transmission is in Park or Neutral to the PCM. When the transmission is in Park or Neutral the Park/Neutral position switch sense circuit is grounded. Possible Causes: - Connector terminals and/or wires - Park/Neutral switch failure - Mechanical transmission problem - PCM failure Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Page 3573 Transmission Position Switch/Sensor: Testing and Inspection Park/Neutral Starting and Back-Up Lamp Switch 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 the switch, remove the wiring connector from the switch and test for continuity between the center pin of the switch and the transaxle case. Continuity should exist only when the transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 1. To test the switch, remove the wiring connector from the switch and test for continuity between the two outside pins. Continuity should only exist with the transaxle in the REVERSE position. 2. No continuity should exist from either pin to the transaxle case. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Page 3574 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Starting and Back-Up Lamp Switch Removal 1. Place a suitable container under the switch to catch fluid when switch is removed. 2. Unscrew switch from transaxle case allowing fluid to drain into container. 3. Move selector lever to PARK, then NEUTRAL position and inspect to see the switch operating lever fingers are centered in the switch opening. Installation 1. Crew the switch with a new seal into the transaxle case and tighten to 33 Nm (24 ft. lbs.). 2. Test switch with a test lamp. 3. Add fluid to transaxle to bring up to proper level. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 678 > Sep > 96 > Recall - Reprogram (flash) PCM Technical Service Bulletin # 678 Date: 960901 Recall - Reprogram (flash) PCM No. 678 September, 1996 To: All California Dodge, Chrysler-Plymouth and Jeep(R) & Eagle Dealers Subject: California Emissions Recall # 678-- Reprogram Powertrain Control Module Models: All Passenger Cars Listed Below Equipped With a California Emission Control System (OBD II) Which Are Currently Located in California: ^ 1996 Model Year Dodge Intrepid, Chrysler Concorde, Chrysler LHS and Eagle Vision (LH) Vehicles Built Through November 5, 1995 (MDH 11O5XX) ^ 1996 Model Year Dodge Stratus, Plymouth Breeze and Chrysler Cirrus (JA) Vehicles Built Through November 5, 1995 (MDH 11O5XX) ^ 1996 Model Year Chrysler Sebring Convertible (JX) Vehicles Built Through November 21, 1995 (MDH 1121XX) ^ 1996 Model Year Dodge and Plymouth Neon (PL) Vehicles Built Through November 12, 1995 (MDH 1112XX) ^ 1995 Model Year Dodge Stratus and Chrysler Cirrus (JA) Vehicles Equipped With a 2.0L Engine and Manual Transmission The On Board Diagnostic (OBDII) readiness codes may be cleared, in violation of California Air Resources Board (CARB) regulations. The readiness codes indicate that all OBDII diagnostic tests have been performed and that diagnostic trouble codes (DTC's) can be read. Absence of readiness codes may cause owners to fail their SMOG Check inspection. To correct this condition, the Powertrain Control Module (PCM) must be reprogrammed (flashed). Important: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for use as proof in renewal of the vehicle registration. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by first class mail. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles as necessary. All other California dealers: Each California Dodge, Chrysler-Plymouth, and Jeep & Eagle dealer who does not receive a Vehicle List will receive a copy of this dealer recall notification letter by first class mail. Non-California Dealers will also receive copies of these recall instructions by CMMS Mail. Some involved vehicles may have been relocated outside of California, and the instructions will allow dealers to perform this service on such vehicles upon request. DIAL System Function 70 and VIP All involved vehicles will be entered to DIAL System Function 70 and VIP at the time of recall implementation for dealer inquiry by VIN as needed. Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall was completed. A label is included in each emissions service parts package. Refer to the Service Procedure of this letter for application instructions. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 678 > Sep > 96 > Recall - Reprogram (flash) PCM > Page 3583 Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Label Packages, Recall PN CHD06780, to service 50% of those vehicles. Each parts package contains an authorized software update label and a recall completion label. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance PCM update previously performed -- Install 08678181 0.2 hours completion label Reprogram Powertrain Control Module 08678182 0.5 hours Add the cost of the recall parts package 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 applicable. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Reprogram the PCM 1. Connect the MDS (Mopar Diagnostic System) and the DRB III (Scan Tool) to the vehicle and power them up. NOTE: The Mopar Diagnostic System is required to perform the PCM reflash. The system must be operating with RELEASE 20 or higher and TIL CD RELEASE 1116 or higher must be installed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 678 > Sep > 96 > Recall - Reprogram (flash) PCM > Page 3584 2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM VEHICLE CONTROLLER on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB Ill which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Step C. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. B. Install Authorized Software Update Label 1. Type the necessary information on the supplied "Authorized Software Update" label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the supplied label. C. Install the Recall Completion Label 1. With a ball point pen, print your dealer code (5 digits) on the supplied Rec Completion Label. 2. Peel the label from its backing and apply it near the Vehicle Emission Con Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle Emission Recall Proof of Correction Form and supply it to the vehicle owner. Owner Letter EMISSIONS RECALL TO REPROGRAM YOUR VEHICLE'S POWERTRAIN CONTROL MODULE Dear Chrysler Passenger Car Owner: It has been determined that some 1995 Chrysler Cirrus and Dodge Stratus; and 1996 Chrysler Cirrus, Concorde, LHS and Sebring Convertible; Dodge Neon, Stratus and Intrepid; Plymouth Breeze and Neon; and Eagle Vision vehicles may be in violation of California Emissions Standards. The problem is... The on-board diagnostic system on your vehicle (identified by the Vehicle Identification Number on the enclosed form), may be missing certain information required by California Air Resources Board (CARB) regulations. Absence of this information will cause your vehicle to fail the required California SMOG Check inspection. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will reprogram the powertrain control module. The service will take about one half hour but additional time may be required depending on how service work is scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 678 > Sep > 96 > Recall - Reprogram (flash) PCM > Page 3585 appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. without the free service we are providing, your vehicle will fail this test. Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed... State of California regulations require Chrysler to provide the Department of Motor Vehicles with a record of all vehicles which have not had the recall service performed. If your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. We are sorry for any inconvenience, but trust you understand our interest in clean air and in your continued satisfaction with our products. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-005-01 > Feb > 01 > PCM - OBDII Readiness Code Retention PROM - Programmable Read Only Memory: Customer Interest PCM - OBDII Readiness Code Retention NUMBER: 18-005-01 GROUP: Vehicle Performance DATE: Feb. 16, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-18-97, DATED MAY 9, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: OBDII Readiness Code Retention OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module. MODELS: 1995-1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (LH) Intrepid/Vision/Concorde/LHS 1996 (PL) Neon NOTE: THIS INFORMATION APPLIES TO FEDERAL EMISSION (SALES CODE NAA) AND CALIFORNIA EMISSION (SALES CODE NAE) MODELS BUILT PRIOR TO NOV. 21, 1995 (MDH1121XX) AND ALL 1995 JA MODELS EQUIPPED WITH A 2.0L ENGINE AND MANUAL TRANSAXLE. THE CALIFORNIA EMISSION MODELS ADDRESSED IN THIS BULLETIN WERE SOLD IN THE NORTHEAST STATES. CALIFORNIA MODELS SOLD IN CALIFORNIA WERE ADDRESSED WITH RECALL 678 DATED SEPT. 1996. DISCUSSION: The On Board Diagnostic (OBDII) system includes a monitor called readiness codes. The readiness codes indicate that all OBDII diagnostic tests have been performed and that diagnostic trouble codes (DTC's) can be read. It has been determined that the readiness codes may be cleared upon ignition key "OFF" cycles. Absence of readiness codes may cause owners to fail their emission inspection. To correct this condition, the Powertrain Control Module (PCM) must be reprogrammed. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING WITH CIS CD2075 OR HIGHER 1. Flash the PCM using the MDS2 (Mopar Diagnostic System) and DRBIII(R) (Scan Tool). NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-005-01 > Feb > 01 > PCM - OBDII Readiness Code Retention > Page 3591 2. Type the necessary information on the Authorized Software Update Label p/n 04669020 (Fig. 1). Attach the label to the PCM and cover it 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: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3596 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3597 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3598 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 180896 > Mar > 96 > PCM - Cold Start Hesitation/Sag/Stumble,Idle Variation PROM - Programmable Read Only Memory: Customer Interest PCM - Cold Start Hesitation/Sag/Stumble,Idle Variation NO: 18-08-96 GROUP: Vehicle Performance DATE: Mar. 8, 1996 SUBJECT: Cold Start Hesitation/Sag/Stumble, A/C Idle Speed Variation and Highway Cycling Effects MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 2.0L SOHC AND DOHC ENGINES (AUTOMATIC AND MANUAL TRANSAXLE) BUILT PRIOR TO FEBRUARY 19, 1996 (MDH 02-19-XX) IN THE BELVEDERE ASSEMBLY PLANT (D IN THE 11TH POSITION OF THE VIN) AND ALL TOLUCA BUILT VEHICLES. SYMPTOM/CONDITION: The following vehicle performance symptoms are substantially improved by the revised software in this bulletin. ^ The engine hesitates on the first few throttle openings following a cold or partial cool down start (more pronounced after overnight soak). ^ Engine RPM surges or dips at idle when A/C cycles. ^ A slight bump, which can be described as a hesitation, is felt at highway speeds when the A/C cycles on or off. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 19 OR HIGHER AND TIL CD RELEASE 1099 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves reprogramming (flashing) the PCM with new software (calibrations). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM VEHICLE CONTROLLER on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 180896 > Mar > 96 > PCM - Cold Start Hesitation/Sag/Stumble,Idle Variation > Page 3603 If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-44-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 183595 > Dec > 95 > PCM - O2 Sensor Faults/MIL ON PROM - Programmable Read Only Memory: Customer Interest PCM - O2 Sensor Faults/MIL ON NO: 18-35-95 GROUP: Vehicle Performance DATE: Dec. 15, 1995 SUBJECT: Rear O2 Sensor Diagnostics / OBD II Protocol MODELS: 1996 (FJ) Avenger/Sebring/Talon 1996 (PL) Neon NOTE: This bulletin applies to 1996 vehicles equipped with a 2.0L engine (Avenger/Sebring/Talon built prior to November 10, 1995 MDH (11-10-xx)) (Neon built prior to November 14, 1995 MDH (11-14-xx)). SYMPTOM/CONDITION: 1. Intermitent rear O2 sensor fault, Diagnostic Trouble Code (DTC) # 129 with Malfunction Indicator Light (MIL) illumination. 2. Inability of generic scan tool to read all Diagnostic Trouble Codes (DTC's). 3. Inability to store OBD II Readiness Codes. EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7010 J1962/MMC Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: The Mopar Diagnostic System may be required to perform part of the repair and the system must be operating with release 18 or higher and TIL CD release 1095 or higher must be installed. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes) for all symptoms listed. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. ^ If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: The following steps are required by law. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 183595 > Dec > 95 > PCM - O2 Sensor Faults/MIL ON > Page 3608 9. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-98 ......................................................................................................................................... .............................. 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3614 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3615 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3616 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3617 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3618 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3619 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3620 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3621 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3622 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3623 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3624 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3625 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3626 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3627 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3628 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3629 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3630 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3631 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3632 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 18-005-01 > Feb > 01 > PCM - OBDII Readiness Code Retention PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - OBDII Readiness Code Retention NUMBER: 18-005-01 GROUP: Vehicle Performance DATE: Feb. 16, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-18-97, DATED MAY 9, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: OBDII Readiness Code Retention OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module. MODELS: 1995-1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (LH) Intrepid/Vision/Concorde/LHS 1996 (PL) Neon NOTE: THIS INFORMATION APPLIES TO FEDERAL EMISSION (SALES CODE NAA) AND CALIFORNIA EMISSION (SALES CODE NAE) MODELS BUILT PRIOR TO NOV. 21, 1995 (MDH1121XX) AND ALL 1995 JA MODELS EQUIPPED WITH A 2.0L ENGINE AND MANUAL TRANSAXLE. THE CALIFORNIA EMISSION MODELS ADDRESSED IN THIS BULLETIN WERE SOLD IN THE NORTHEAST STATES. CALIFORNIA MODELS SOLD IN CALIFORNIA WERE ADDRESSED WITH RECALL 678 DATED SEPT. 1996. DISCUSSION: The On Board Diagnostic (OBDII) system includes a monitor called readiness codes. The readiness codes indicate that all OBDII diagnostic tests have been performed and that diagnostic trouble codes (DTC's) can be read. It has been determined that the readiness codes may be cleared upon ignition key "OFF" cycles. Absence of readiness codes may cause owners to fail their emission inspection. To correct this condition, the Powertrain Control Module (PCM) must be reprogrammed. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING WITH CIS CD2075 OR HIGHER 1. Flash the PCM using the MDS2 (Mopar Diagnostic System) and DRBIII(R) (Scan Tool). NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 18-005-01 > Feb > 01 > PCM - OBDII Readiness Code Retention > Page 3637 2. Type the necessary information on the Authorized Software Update Label p/n 04669020 (Fig. 1). Attach the label to the PCM and cover it 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: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3642 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3643 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3644 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 678 > Sep > 96 > Recall - Reprogram (flash) PCM Technical Service Bulletin # 678 Date: 960901 Recall - Reprogram (flash) PCM No. 678 September, 1996 To: All California Dodge, Chrysler-Plymouth and Jeep(R) & Eagle Dealers Subject: California Emissions Recall # 678-- Reprogram Powertrain Control Module Models: All Passenger Cars Listed Below Equipped With a California Emission Control System (OBD II) Which Are Currently Located in California: ^ 1996 Model Year Dodge Intrepid, Chrysler Concorde, Chrysler LHS and Eagle Vision (LH) Vehicles Built Through November 5, 1995 (MDH 11O5XX) ^ 1996 Model Year Dodge Stratus, Plymouth Breeze and Chrysler Cirrus (JA) Vehicles Built Through November 5, 1995 (MDH 11O5XX) ^ 1996 Model Year Chrysler Sebring Convertible (JX) Vehicles Built Through November 21, 1995 (MDH 1121XX) ^ 1996 Model Year Dodge and Plymouth Neon (PL) Vehicles Built Through November 12, 1995 (MDH 1112XX) ^ 1995 Model Year Dodge Stratus and Chrysler Cirrus (JA) Vehicles Equipped With a 2.0L Engine and Manual Transmission The On Board Diagnostic (OBDII) readiness codes may be cleared, in violation of California Air Resources Board (CARB) regulations. The readiness codes indicate that all OBDII diagnostic tests have been performed and that diagnostic trouble codes (DTC's) can be read. Absence of readiness codes may cause owners to fail their SMOG Check inspection. To correct this condition, the Powertrain Control Module (PCM) must be reprogrammed (flashed). Important: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for use as proof in renewal of the vehicle registration. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by first class mail. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles as necessary. All other California dealers: Each California Dodge, Chrysler-Plymouth, and Jeep & Eagle dealer who does not receive a Vehicle List will receive a copy of this dealer recall notification letter by first class mail. Non-California Dealers will also receive copies of these recall instructions by CMMS Mail. Some involved vehicles may have been relocated outside of California, and the instructions will allow dealers to perform this service on such vehicles upon request. DIAL System Function 70 and VIP All involved vehicles will be entered to DIAL System Function 70 and VIP at the time of recall implementation for dealer inquiry by VIN as needed. Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall was completed. A label is included in each emissions service parts package. Refer to the Service Procedure of this letter for application instructions. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 678 > Sep > 96 > Recall - Reprogram (flash) PCM > Page 3649 Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Label Packages, Recall PN CHD06780, to service 50% of those vehicles. Each parts package contains an authorized software update label and a recall completion label. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance PCM update previously performed -- Install 08678181 0.2 hours completion label Reprogram Powertrain Control Module 08678182 0.5 hours Add the cost of the recall parts package 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 applicable. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Reprogram the PCM 1. Connect the MDS (Mopar Diagnostic System) and the DRB III (Scan Tool) to the vehicle and power them up. NOTE: The Mopar Diagnostic System is required to perform the PCM reflash. The system must be operating with RELEASE 20 or higher and TIL CD RELEASE 1116 or higher must be installed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 678 > Sep > 96 > Recall - Reprogram (flash) PCM > Page 3650 2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM VEHICLE CONTROLLER on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB Ill which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Step C. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. B. Install Authorized Software Update Label 1. Type the necessary information on the supplied "Authorized Software Update" label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the supplied label. C. Install the Recall Completion Label 1. With a ball point pen, print your dealer code (5 digits) on the supplied Rec Completion Label. 2. Peel the label from its backing and apply it near the Vehicle Emission Con Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle Emission Recall Proof of Correction Form and supply it to the vehicle owner. Owner Letter EMISSIONS RECALL TO REPROGRAM YOUR VEHICLE'S POWERTRAIN CONTROL MODULE Dear Chrysler Passenger Car Owner: It has been determined that some 1995 Chrysler Cirrus and Dodge Stratus; and 1996 Chrysler Cirrus, Concorde, LHS and Sebring Convertible; Dodge Neon, Stratus and Intrepid; Plymouth Breeze and Neon; and Eagle Vision vehicles may be in violation of California Emissions Standards. The problem is... The on-board diagnostic system on your vehicle (identified by the Vehicle Identification Number on the enclosed form), may be missing certain information required by California Air Resources Board (CARB) regulations. Absence of this information will cause your vehicle to fail the required California SMOG Check inspection. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will reprogram the powertrain control module. The service will take about one half hour but additional time may be required depending on how service work is scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 678 > Sep > 96 > Recall - Reprogram (flash) PCM > Page 3651 appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. without the free service we are providing, your vehicle will fail this test. Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed... State of California regulations require Chrysler to provide the Department of Motor Vehicles with a record of all vehicles which have not had the recall service performed. If your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. We are sorry for any inconvenience, but trust you understand our interest in clean air and in your continued satisfaction with our products. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 180896 > Mar > 96 > PCM - Cold Start Hesitation/Sag/Stumble,Idle Variation PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Cold Start Hesitation/Sag/Stumble,Idle Variation NO: 18-08-96 GROUP: Vehicle Performance DATE: Mar. 8, 1996 SUBJECT: Cold Start Hesitation/Sag/Stumble, A/C Idle Speed Variation and Highway Cycling Effects MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 2.0L SOHC AND DOHC ENGINES (AUTOMATIC AND MANUAL TRANSAXLE) BUILT PRIOR TO FEBRUARY 19, 1996 (MDH 02-19-XX) IN THE BELVEDERE ASSEMBLY PLANT (D IN THE 11TH POSITION OF THE VIN) AND ALL TOLUCA BUILT VEHICLES. SYMPTOM/CONDITION: The following vehicle performance symptoms are substantially improved by the revised software in this bulletin. ^ The engine hesitates on the first few throttle openings following a cold or partial cool down start (more pronounced after overnight soak). ^ Engine RPM surges or dips at idle when A/C cycles. ^ A slight bump, which can be described as a hesitation, is felt at highway speeds when the A/C cycles on or off. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 19 OR HIGHER AND TIL CD RELEASE 1099 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves reprogramming (flashing) the PCM with new software (calibrations). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM VEHICLE CONTROLLER on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 180896 > Mar > 96 > PCM - Cold Start Hesitation/Sag/Stumble,Idle Variation > Page 3656 If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-44-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 183595 > Dec > 95 > PCM - O2 Sensor Faults/MIL ON PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - O2 Sensor Faults/MIL ON NO: 18-35-95 GROUP: Vehicle Performance DATE: Dec. 15, 1995 SUBJECT: Rear O2 Sensor Diagnostics / OBD II Protocol MODELS: 1996 (FJ) Avenger/Sebring/Talon 1996 (PL) Neon NOTE: This bulletin applies to 1996 vehicles equipped with a 2.0L engine (Avenger/Sebring/Talon built prior to November 10, 1995 MDH (11-10-xx)) (Neon built prior to November 14, 1995 MDH (11-14-xx)). SYMPTOM/CONDITION: 1. Intermitent rear O2 sensor fault, Diagnostic Trouble Code (DTC) # 129 with Malfunction Indicator Light (MIL) illumination. 2. Inability of generic scan tool to read all Diagnostic Trouble Codes (DTC's). 3. Inability to store OBD II Readiness Codes. EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7010 J1962/MMC Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: The Mopar Diagnostic System may be required to perform part of the repair and the system must be operating with release 18 or higher and TIL CD release 1095 or higher must be installed. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes) for all symptoms listed. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. ^ If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: The following steps are required by law. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 183595 > Dec > 95 > PCM - O2 Sensor Faults/MIL ON > Page 3661 9. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-98 ......................................................................................................................................... .............................. 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3667 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3668 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3669 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3670 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3671 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3672 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3673 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3674 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3675 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3676 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3677 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3678 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3679 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3680 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3681 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3682 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3683 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3684 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3685 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 18-005-01 > Feb > 01 > PCM - OBDII Readiness Code Retention PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - OBDII Readiness Code Retention NUMBER: 18-005-01 GROUP: Vehicle Performance DATE: Feb. 16, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-18-97, DATED MAY 9, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: OBDII Readiness Code Retention OVERVIEW: This bulletin involves reprogramming the Powertrain Control Module. MODELS: 1995-1996 (JA) Cirrus/Stratus/Breeze 1996 (JX) Sebring Convertible 1996 (LH) Intrepid/Vision/Concorde/LHS 1996 (PL) Neon NOTE: THIS INFORMATION APPLIES TO FEDERAL EMISSION (SALES CODE NAA) AND CALIFORNIA EMISSION (SALES CODE NAE) MODELS BUILT PRIOR TO NOV. 21, 1995 (MDH1121XX) AND ALL 1995 JA MODELS EQUIPPED WITH A 2.0L ENGINE AND MANUAL TRANSAXLE. THE CALIFORNIA EMISSION MODELS ADDRESSED IN THIS BULLETIN WERE SOLD IN THE NORTHEAST STATES. CALIFORNIA MODELS SOLD IN CALIFORNIA WERE ADDRESSED WITH RECALL 678 DATED SEPT. 1996. DISCUSSION: The On Board Diagnostic (OBDII) system includes a monitor called readiness codes. The readiness codes indicate that all OBDII diagnostic tests have been performed and that diagnostic trouble codes (DTC's) can be read. It has been determined that the readiness codes may be cleared upon ignition key "OFF" cycles. Absence of readiness codes may cause owners to fail their emission inspection. To correct this condition, the Powertrain Control Module (PCM) must be reprogrammed. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING WITH CIS CD2075 OR HIGHER 1. Flash the PCM using the MDS2 (Mopar Diagnostic System) and DRBIII(R) (Scan Tool). NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 18-005-01 > Feb > 01 > PCM - OBDII Readiness Code Retention > Page 3690 2. Type the necessary information on the Authorized Software Update Label p/n 04669020 (Fig. 1). Attach the label to the PCM and cover it 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: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3695 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3696 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3697 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 180896 > Mar > 96 > PCM - Cold Start Hesitation/Sag/Stumble,Idle Variation PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Cold Start Hesitation/Sag/Stumble,Idle Variation NO: 18-08-96 GROUP: Vehicle Performance DATE: Mar. 8, 1996 SUBJECT: Cold Start Hesitation/Sag/Stumble, A/C Idle Speed Variation and Highway Cycling Effects MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 2.0L SOHC AND DOHC ENGINES (AUTOMATIC AND MANUAL TRANSAXLE) BUILT PRIOR TO FEBRUARY 19, 1996 (MDH 02-19-XX) IN THE BELVEDERE ASSEMBLY PLANT (D IN THE 11TH POSITION OF THE VIN) AND ALL TOLUCA BUILT VEHICLES. SYMPTOM/CONDITION: The following vehicle performance symptoms are substantially improved by the revised software in this bulletin. ^ The engine hesitates on the first few throttle openings following a cold or partial cool down start (more pronounced after overnight soak). ^ Engine RPM surges or dips at idle when A/C cycles. ^ A slight bump, which can be described as a hesitation, is felt at highway speeds when the A/C cycles on or off. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order for future reference and repair as necessary. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 19 OR HIGHER AND TIL CD RELEASE 1099 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves reprogramming (flashing) the PCM with new software (calibrations). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM VEHICLE CONTROLLER on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 180896 > Mar > 96 > PCM - Cold Start Hesitation/Sag/Stumble,Idle Variation > Page 3702 If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plastic sticker 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-44-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 183595 > Dec > 95 > PCM - O2 Sensor Faults/MIL ON PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - O2 Sensor Faults/MIL ON NO: 18-35-95 GROUP: Vehicle Performance DATE: Dec. 15, 1995 SUBJECT: Rear O2 Sensor Diagnostics / OBD II Protocol MODELS: 1996 (FJ) Avenger/Sebring/Talon 1996 (PL) Neon NOTE: This bulletin applies to 1996 vehicles equipped with a 2.0L engine (Avenger/Sebring/Talon built prior to November 10, 1995 MDH (11-10-xx)) (Neon built prior to November 14, 1995 MDH (11-14-xx)). SYMPTOM/CONDITION: 1. Intermitent rear O2 sensor fault, Diagnostic Trouble Code (DTC) # 129 with Malfunction Indicator Light (MIL) illumination. 2. Inability of generic scan tool to read all Diagnostic Trouble Codes (DTC's). 3. Inability to store OBD II Readiness Codes. EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7010 J1962/MMC Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: The Mopar Diagnostic System may be required to perform part of the repair and the system must be operating with release 18 or higher and TIL CD release 1095 or higher must be installed. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes) for all symptoms listed. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. ^ If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: The following steps are required by law. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 183595 > Dec > 95 > PCM - O2 Sensor Faults/MIL ON > Page 3707 9. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-43-98 ......................................................................................................................................... .............................. 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3713 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3714 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3715 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3716 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3717 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3718 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3719 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3720 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3721 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3722 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3723 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3724 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3725 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3726 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 3727 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3728 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3729 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3730 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3731 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 678 > Sep > 96 > Recall - Reprogram (flash) PCM Technical Service Bulletin # 678 Date: 960901 Recall - Reprogram (flash) PCM No. 678 September, 1996 To: All California Dodge, Chrysler-Plymouth and Jeep(R) & Eagle Dealers Subject: California Emissions Recall # 678-- Reprogram Powertrain Control Module Models: All Passenger Cars Listed Below Equipped With a California Emission Control System (OBD II) Which Are Currently Located in California: ^ 1996 Model Year Dodge Intrepid, Chrysler Concorde, Chrysler LHS and Eagle Vision (LH) Vehicles Built Through November 5, 1995 (MDH 11O5XX) ^ 1996 Model Year Dodge Stratus, Plymouth Breeze and Chrysler Cirrus (JA) Vehicles Built Through November 5, 1995 (MDH 11O5XX) ^ 1996 Model Year Chrysler Sebring Convertible (JX) Vehicles Built Through November 21, 1995 (MDH 1121XX) ^ 1996 Model Year Dodge and Plymouth Neon (PL) Vehicles Built Through November 12, 1995 (MDH 1112XX) ^ 1995 Model Year Dodge Stratus and Chrysler Cirrus (JA) Vehicles Equipped With a 2.0L Engine and Manual Transmission The On Board Diagnostic (OBDII) readiness codes may be cleared, in violation of California Air Resources Board (CARB) regulations. The readiness codes indicate that all OBDII diagnostic tests have been performed and that diagnostic trouble codes (DTC's) can be read. Absence of readiness codes may cause owners to fail their SMOG Check inspection. To correct this condition, the Powertrain Control Module (PCM) must be reprogrammed (flashed). Important: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal. The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for use as proof in renewal of the vehicle registration. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by first class mail. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles as necessary. All other California dealers: Each California Dodge, Chrysler-Plymouth, and Jeep & Eagle dealer who does not receive a Vehicle List will receive a copy of this dealer recall notification letter by first class mail. Non-California Dealers will also receive copies of these recall instructions by CMMS Mail. Some involved vehicles may have been relocated outside of California, and the instructions will allow dealers to perform this service on such vehicles upon request. DIAL System Function 70 and VIP All involved vehicles will be entered to DIAL System Function 70 and VIP at the time of recall implementation for dealer inquiry by VIN as needed. Recall Completion Label Requirement There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall was completed. A label is included in each emissions service parts package. Refer to the Service Procedure of this letter for application instructions. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 678 > Sep > 96 > Recall - Reprogram (flash) PCM > Page 3736 Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Label Packages, Recall PN CHD06780, to service 50% of those vehicles. Each parts package contains an authorized software update label and a recall completion label. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance PCM update previously performed -- Install 08678181 0.2 hours completion label Reprogram Powertrain Control Module 08678182 0.5 hours Add the cost of the recall parts package 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 applicable. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Reprogram the PCM 1. Connect the MDS (Mopar Diagnostic System) and the DRB III (Scan Tool) to the vehicle and power them up. NOTE: The Mopar Diagnostic System is required to perform the PCM reflash. The system must be operating with RELEASE 20 or higher and TIL CD RELEASE 1116 or higher must be installed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 678 > Sep > 96 > Recall - Reprogram (flash) PCM > Page 3737 2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAM VEHICLE CONTROLLER on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB Ill which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Step C. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. B. Install Authorized Software Update Label 1. Type the necessary information on the supplied "Authorized Software Update" label (Figure 1) and attach it to the PCM. Cover the label with the clear plastic portion of the supplied label. C. Install the Recall Completion Label 1. With a ball point pen, print your dealer code (5 digits) on the supplied Rec Completion Label. 2. Peel the label from its backing and apply it near the Vehicle Emission Con Information Label located in the engine compartment. D. Complete Proof of Correction Form 1. Complete a Vehicle Emission Recall Proof of Correction Form and supply it to the vehicle owner. Owner Letter EMISSIONS RECALL TO REPROGRAM YOUR VEHICLE'S POWERTRAIN CONTROL MODULE Dear Chrysler Passenger Car Owner: It has been determined that some 1995 Chrysler Cirrus and Dodge Stratus; and 1996 Chrysler Cirrus, Concorde, LHS and Sebring Convertible; Dodge Neon, Stratus and Intrepid; Plymouth Breeze and Neon; and Eagle Vision vehicles may be in violation of California Emissions Standards. The problem is... The on-board diagnostic system on your vehicle (identified by the Vehicle Identification Number on the enclosed form), may be missing certain information required by California Air Resources Board (CARB) regulations. Absence of this information will cause your vehicle to fail the required California SMOG Check inspection. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will reprogram the powertrain control module. The service will take about one half hour but additional time may be required depending on how service work is scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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: > 678 > Sep > 96 > Recall - Reprogram (flash) PCM > Page 3738 appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you don't get this done... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. without the free service we are providing, your vehicle will fail this test. Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed... State of California regulations require Chrysler to provide the Department of Motor Vehicles with a record of all vehicles which have not had the recall service performed. If your vehicle is not on this list, the state will know that the recall has been completed. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. We are sorry for any inconvenience, but trust you understand our interest in clean air and in your continued satisfaction with our products. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Specifications Torque Converter Clutch Solenoid: Specifications The Torque Converter Clutch Solenoid ( TCCS ) if good should measure between 30 to 50 OHMS. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Component Locations Torque Converter Clutch Solenoid: Component Locations The Torque Converter Clutch Solenoid is located on the Valve Body. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Component Locations > Page 3747 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3748 Transmission Control Solenoid Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 3749 Torque Converter Clutch Solenoid: Testing and Inspection The Transmission Torque Converter Clutch Solenoid is diagnosed using powertrain diagnostic trouble codes ( DTC ). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications The Torque Converter Clutch Solenoid ( TCCS ) if good should measure between 30 to 50 OHMS. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Torque Converter Clutch Solenoid: Component Locations The Torque Converter Clutch Solenoid is located on the Valve Body. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 3757 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3758 Transmission Control Solenoid Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3759 Torque Converter Clutch Solenoid: Testing and Inspection The Transmission Torque Converter Clutch Solenoid is diagnosed using powertrain diagnostic trouble codes ( DTC ). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Kickdown Band: Specifications Kickdown band adjustment 45 - 50 in.lb Then back off 2 1/2 turns. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Kickdown > Page 3764 Band: Specifications Low/Reverse band adjustment 41 in.lb Then back off 3 1/2 turns. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Page 3765 Band: Adjustments KICKDOWN BAND (FRONT) The kickdown band adjusting screw is located on left side (top front) of the transaxle case. 1. Loosen locknut and back-off nut approximately five turns. Test adjusting screw for free turning in the transaxle case. 2. Using wrench, tighten adjusting screw to 8 Nm (72 inch lbs.). 3. Back-off adjusting screw 2 1/4 turns. Hold adjusting screw in this position and tighten locknut to 47 Nm (35 ft. lbs.) LOW/REVERSE BAND (REAR) To adjust low/reverse band, proceed as follows: 1. Loosen and back off locknut approximately five turns. 2. Using an inch-pound torque wrench, tighten adjusting screw to 5 Nm (41 inch lbs.) true torque. 3. Back-off adjusting screw 3 1/2 turns. 4. Tighten locknut to 14 Nm (10 ft. lbs.). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications Clutch: Specifications CLEARANCES: Front Clutch (Non-Adjustable)* ................................................................................................................................ 1.27 - 2.79 mm (0.050 - 0.110 inch) Rear Clutch 4 Disc (Adjustable) ............................................................................................................................... 0.71 - 1.10 mm (0.028 - 0.043 inch) SELECTIVE SNAP RINGS: Size 1 ................................................................................................................................................... ...................... 1.22 - 1.27 mm (0.048 - 0.050 inch) Size 2 .................................................................. ....................................................................................................... 1.52 - 1.57 mm (0.060 - 0.062 inch) Size 3 .......................................................................................................................................... ............................... 1.73 - 1.78 mm (0.068 - 0.070 inch) Size 4 ......................................................... ................................................................................................................ 1.88 - 1.93 mm (0.074 0.076 inch) Size 5 ................................................................................................................................ ......................................... 2.21 - 2.26 mm (0.087 - 0.089 inch) * NOTE: Measured From Reaction Plate To "Farthest Wave" On A 4 Disc Setup. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Page 3769 Measuring Rear Clutch Plate Clearance Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Transfer Shaft, A/T > Component Information > Service and Repair Differential Transfer Shaft: Service and Repair 1. Remove rear cover attaching bolts and rear cover. Fig. 5 Transfer Shaft Gear Nut Removal 2. Using transfer shaft gear tool No. L-4434, or equivalent, remove transfer shaft gear retaining nut, Fig.5. Fig. 6 Transfer Shaft Gear Removal 3. Using transfer shaft gear puller tool No. L-4407, or equivalent, remove transfer shaft gear and shim, Fig.6. 4. Remove governor support retainer, then remove low-reverse band anchor pin. 5. Remove governor assembly. 6. Remove transfer shaft retainer snap ring, then using transfer shaft and bearing retainer removal tool No. L-4512, or equivalent and a suitable puller, remove transfer shaft and retainer assembly. 7. Remove transfer shaft retainer from shaft. 8. Using a screwdriver, remove oil seal from transfer shaft retainer. 9. Using suitable tool, tap oil seal into shaft retainer. 10. Reverse procedure to install. Torque transfer shaft gear retaining nut to 200 ft. lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3781 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3782 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3783 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3784 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 3785 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Estimated service refill ......................................................................................................................... ............................................................. 3.8L (4.0 Qt) Overhaul refill with torque converter ................. ............................................................................................................................................... 8.2L (8.8 Qt) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3788 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ............................................................................................................ ................................................................................... MOPAR ATF Type 9602 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair Governor: Service and Repair The governor assembly can be removed for reconditioning or replacement without removing the transfer gear cover, transfer gear and governor support. To remove governor, drain transmission fluid and remove transmission oil pan. Remove valve body, unbolt governor from governor support, then remove governor. When cleaning or assembling the governor assembly, ensure governor valves move freely in governor body bores. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation CIRCUIT OPERATION The PRNDL lamp receives power on the E2 circuit from the 4 Amp fuse located in the fuse block in cavity 12. The fuse receives power from the headlamp switch. Circuit E2 also powers the ash receiver lamp. When the headlamp switch is moved to the PARK or ON position, current flows through the fuse to the PRNDL lamp. The ground for the lamp is supplied on the Z3 circuit, and terminates at the instrument panel left center support. This circuit is also spliced in with the ash receiver lamp, the ignition switch lamp, and the glove box lamp. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > A/T Pan Gasket - Reusable Design/Installation Technical Service Bulletin # 21-05-99A Date: 990903 A/T Pan Gasket - Reusable Design/Installation NUMBER: 21-05-99 Rev. A GROUP: Transmission DATE: Sep. 03, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-05-99 DATED MARCH 5, 1999 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND MODEL COVERAGE. SUBJECT: Reusable Automatic Transmission Oil Pan Gasket OVERVIEW: This bulletin announces availability and installation of a reusable automatic transmission oil pan gasket. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon **1989** - 1993 (AG) Daytona **1989** - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1989** - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (European Market) 1995 - **2000** (JA) Cirrus/Stratus/Breeze 1996 - **2000** (JX) Sebring Convertible **1993 - 2000 (LH) Concorde/Intrepid/New Yorker/LHS/Vision/300M** 1996 - **2000** (NS) Town & Country/Caravan/Voyager **1995 - 2000 (PL) Neon** **1997 - 2000 (PR) Prowler** DISCUSSION: A reusable silicone gasket has been developed to replace the RTV method of sealing the automatic transmission oil pan. Due to more frequent Automatic Transmission Fluid (ATF) change intervals and the possibility of the fluid foaming if it comes in contact with uncured RTV it is recommended that this gasket be used in all applications. NOTE: THIS GASKET CAN BE REUSED UP TO THREE (3) TIMES. PARTS REQUIRED: **1 05011113AA Gasket, Transmission Oil Pan, 31TH** **1 05011114AA Gasket, Transmission Oil Pan, 42LE** 1 05011115AA Gasket, Transmission Oil Pan, 41TE/AE POLICY: INFORMATION ONLY POLICY: Information Only Installation Procedure 1. With oil pan removed from transmission case for routine service or transmission repair proceed to step # 2. 2. Clean any residue from oil pan and magnet. 3. Replace O-ring and filter on bottom of valve body. 4. Using a plastic or wooden scraper, remove old RTV from transmission case rails. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > A/T Pan Gasket - Reusable Design/Installation > Page 3804 CAUTION: ALUMINUM COMPONENTS ARE VERY SUSCEPTABLE TO METAL TRANSFER WHEN OLD GASKET MATERIAL IS REMOVED FROM THEM. USE EXTREME CARE WHEN CLEANING THESE COMPONENTS. 5. Apply thin coat of transmission fluid to oil pan and transmission case pan rails. 6. Orient reusable gasket properly with bolt holes and assemble oil pan and gasket to transmission case. Tighten oil pan bolts to 19 Nm (165 in lbs.). 7. Refill transmission to the proper level with MOPAR ATF + 3 Type 7176, p/n 05010124AA, or MOPAR ATF +4 Type 9602, p/n 05013457AA, for 1999 JA/LH/PR vehicles. CAUTION: DO NOT OVERFILL TRANSAXLE. DO NOT ADD OIL IF LEVEL IS BETWEEN: LOWER HOLES FOR WARM OIL (100°F). UPPER HOLES FOR HOT OIL (180°F.). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Throttle Position Sensor Mounting Screws 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3809 Transmission Connections Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3812 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3813 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3814 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3815 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3816 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3817 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3818 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3819 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3820 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3821 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3822 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3823 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3824 Transmission Position Switch/Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3825 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3826 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3827 Rear Lighting (Part 1 Of 3) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Park/Neutral Position Switch Operation Transmission Position Switch/Sensor: Description and Operation Park/Neutral Position Switch Operation Fig. 20 Park/Neutral Switch OPERATION The park/neutral position switch is located on the automatic transaxle housing Fig. 20. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. CIRCUIT OPERATION When CLOSED the Transmission Range Switch (TRS) provides an input to the Powertrain Control Module (PCM) on circuit T41. This circuit connects to cavity 76 of the PCM connector. The T41 circuit is spliced and provides a ground path for the engine starter relay, and the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Park/Neutral Position Switch Operation > Page 3830 Transmission Position Switch/Sensor: Description and Operation Park/Neutral Switch Failure Trouble Code Name of Code: Park/Neutral Switch Failure (Sense Circuit) When Monitored: With the transmission in Park, Neutral, or Drive and not in limp-in mode. Set Condition: This code is set if the PCM detects an incorrect Park/Neutral switch state for a given mode of vehicle operation. Theory of Operation: The Transmission range Sensor (Park/Neutral position switch on 3 speed auto and all manual trans) is used to communicate whether or not the transmission is in Park or Neutral to the PCM. When the transmission is in Park or Neutral the Park/Neutral position switch sense circuit is grounded. Possible Causes: - Connector terminals and/or wires - Park/Neutral switch failure - Mechanical transmission problem - PCM failure Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 3831 Transmission Position Switch/Sensor: Testing and Inspection Park/Neutral Starting and Back-Up Lamp Switch 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 the switch, remove the wiring connector from the switch and test for continuity between the center pin of the switch and the transaxle case. Continuity should exist only when the transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 1. To test the switch, remove the wiring connector from the switch and test for continuity between the two outside pins. Continuity should only exist with the transaxle in the REVERSE position. 2. No continuity should exist from either pin to the transaxle case. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 3832 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Starting and Back-Up Lamp Switch Removal 1. Place a suitable container under the switch to catch fluid when switch is removed. 2. Unscrew switch from transaxle case allowing fluid to drain into container. 3. Move selector lever to PARK, then NEUTRAL position and inspect to see the switch operating lever fingers are centered in the switch opening. Installation 1. Crew the switch with a new seal into the transaxle case and tighten to 33 Nm (24 ft. lbs.). 2. Test switch with a test lamp. 3. Add fluid to transaxle to bring up to proper level. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Adjustments Shift Interlock Cable: Adjustments 1. Disconnect battery ground cable, then remove console assembly. 2. Remove gearshift knob set screw and knob. 3. Remove gearshift indicator bezel and indicator lamp, then install gearshift knob. 4. Place shifter in Park position. 5. Place ignition in Lock or Accessory position. If cable is out of adjustment, then grasp slug on interlock cable with a suitable pair of pliers and pull back on cable. This will allow ignition to be placed in position. 6. Ensure interlock cable is completely seated into shifter interlock lever, then ensure ignition is in Lock or Accessory position. 7. Pry up adjuster lock on interlock cable. Spring on interlock cable should automatically adjust for slack in cable. 8. Snap interlock cable adjuster lock onto cable. 9. Remove gearshift knob set screw and knob. 10. Install indicator lamp, gearshift bezel and gearshift knob. 11. Connect battery ground cable. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Cable > Component Information > Adjustments > Page 3837 Shift Interlock Cable: Service and Repair 1. Disconnect battery ground cable, then remove console assembly. 2. Remove gearshift knob set screw and knob. 3. Remove gearshift bezel and indicator lamp. 4. Pry up adjuster lock on interlock cable. 5. Pull cable up and out of gearshift assembly. 6. Remove lower steering column cover and liner. 7. Lift top cover and cluster bezel until clips disengage to provide clearance. 8. Place ignition in On position. 9. Insert a screwdriver into access hole in lower shroud and depress cylinder button while rotating cylinder to disengage it from column. 10. Remove upper and lower shrouds. 11. Disconnect interlock cable from interlock assembly, then remove interlock cable. 12. Reverse procedure to install. Adjust interlock cable as described under Adjustments. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments Shift Cable: Adjustments 1. Set parking brake, then remove floor console. 2. Place gear selector lever in (P) park position, then unsnap collar at shifter cable. 3. Move gear selector lever on transaxle to park position, then verify that both shifter lever and transaxle are in park position. 4. Rotate collar on shift cable adjuster until it seats against plastic housing, Fig.4. Collar must seat against plastic housing to achieve required detent lock position. 5. Inspect adjustment as follows: a. Detent position for neutral and drive should be within limits of hand lever gate stops. b. Key start must occur only when shift lever is in neutral or park positions. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > Customer Interest for Throttle Valve Cable/Linkage: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift Throttle Valve Cable/Linkage: Customer Interest A/T - Slips on Light 2-3 Upshift NO: 21-23-95 Rev. A GROUP: Transmission DATE: Jan. 26, 1996 SUBJECT: Transaxle Slips Momentarily During Light Throttle 2-3 Upshifts NOTE: This bulletin supersedes Technical Service Bulletin 21-23-95, dated Dec. 22, 1995, which should be removed from your files. A labor operation number is revised and highlighted with **asterisks**. MODELS: 1995 - 1996 (PL) Neon NOTE: This bulletin applies to vehicles equipped with a 31TH Transaxle. SYMPTOM/CONDITION: Transaxle slips momentarily (engine RPM increases/flares) during light throttle 2-3 upshifts. DIAGNOSIS: Road test the vehicle. Accelerate at light throttle to achieve a 2-3 upshift at 18-22 MPH and listen for the engine to flare. If the engine flares during the 2-3 upshift, perform the Repair Procedure. PARTS REQUIRED: 1 (AR) 4669863 Bracket, Kickdown With Single Over Head Cam (SOHC) Engine 1 (AR) 4569864 Bracket, Kickdown With Double Over Head Cam (DOHC) Engine 1 (AR) 4659879 Valve Body 1 (AR) 4269649 Filter, Transaxle Oil AR 4798233 Fluid, Mopar Automatic Transmission Type 7176 REPAIR PROCEDURE: This bulletin involves adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and valve body and adjusting the throttle pressure cable. 1. Check the throttle pressure cable for proper adjustment (there should be no backlash) adjust if needed, use the following procedure while the engine is at normal operating temperature: A. Release the cross-lock on the throttle pressure cable assembly (pull the cross-lock up). Refer to Figure 1. B. To ensure proper adjustment, the cable must be free to slide all the way toward the engine (against its internal stop) after the cross-lock is released. Move the transaxle throttle control leveler fully clockwise (against its internal stop) and press the cross-lock down into the locked position. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > Customer Interest for Throttle Valve Cable/Linkage: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 3850 Adjustment is now complete and any throttle cable backlash has been automatically removed. Test the throttle pressure cable assembly for freedom of operation by moving the transaxle throttle control lever forward (counterclockwise). Then slowly release the lever to confirm it will return fully rearward (clockwise). No lubrication is required for the throttle cable system. C. Road test the vehicle to verify the flare condition is corrected. 2. If the flare condition persists, replace the kickdown bracket on the throttle body with the appropriate bracket specified in the Parts Required section of this bulletin. Then perform Step 1 again. 3. If the flare condition persists, replace the transaxle valve body (P/N 4659879), use the following procedure: A. Record the radio station presets and disconnect the battery cables. B. Pull the Power Distribution Center (PDC) up and out of its holding bracket. Set the PDC aside to gain clearance. C. Remove the battery from the vehicle and disconnect the cruise control, if equipped. D. Loosen the throttle pressure cable lever and gear shift cable lever pinch bolts. Refer to Figure 2. Remove both levers from their shafts and set aside. E. Raise the vehicle on an appropriate hoist. F. Clean the bottom of the transaxle. G. Remove the transaxle oil pan and properly dispose of the fluid. Be sure to remove all sealant from the mating surfaces. H. Remove the neutral start/back-up lamp switch. Refer to Figure 3. I. Remove and discard the transaxle oil filter. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > Customer Interest for Throttle Valve Cable/Linkage: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 3851 J. Remove the "E"-clip holding the parking rod to the valve body and separate the rod from the valve body. Refer to Figure 4. K. Remove the 7 bolts attaching the valve body to the transaxle and separate the valve body and governor tubes from the transaxle. Refer to Figure 5. L. Install the new valve body (P/N 4659879) and governor tubes to the transaxle, torque the 7 attaching bolts to 105 in. lbs. (12 Nm). M. Install the parking rod and secure with the "E"-clip previously removed. N. Install a new transaxle oil filter (P/N 4269649), torque the screws to 40 in. lbs. (5 Nm). 0. Install the neutral start/back-up lamp switch. P. Apply a 1/8 in. (3 mm) bead of Mopar Silicone Sealant (P/N 4318025) to the transaxle oil pan mounting flange. Attach the transaxle oil pan to the transaxle and torque the attaching bolts to 165 in. lbs. (19 Nm). Q. Install the throttle pressure cable lever and gear shift cable lever on their shafts and tighten their pinch bolts. R. Lower the vehicle and connect the cruise control, if equipped. S. Install the battery, PDC and connect the battery cables. T. Add 4 quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. U. Start the engine, and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. V. Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. W. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. X. Repeat Step 1 of this bulletin. Y. Program the previously recorded radio station presets, and set the clock. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > Customer Interest for Throttle Valve Cable/Linkage: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 3852 TIME ALLOWANCE: Labor Operation No: **21-75-32-93** Throttle Press. Cable, Adj. & Road Test 0.4 Hrs. FAILURE CODE: XX - Service Adjustment TIME ALLOWANCE: Labor Operation No: 21-75-32-91 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket Adj. Throttle Press. Cable & Road Test 1.0 Hrs. 21-75-32-92 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket & Valve Body Adj. Throttle Press. Cable & Road Test 2.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Valve Cable/Linkage: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift Throttle Valve Cable/Linkage: All Technical Service Bulletins A/T - Slips on Light 2-3 Upshift NO: 21-23-95 Rev. A GROUP: Transmission DATE: Jan. 26, 1996 SUBJECT: Transaxle Slips Momentarily During Light Throttle 2-3 Upshifts NOTE: This bulletin supersedes Technical Service Bulletin 21-23-95, dated Dec. 22, 1995, which should be removed from your files. A labor operation number is revised and highlighted with **asterisks**. MODELS: 1995 - 1996 (PL) Neon NOTE: This bulletin applies to vehicles equipped with a 31TH Transaxle. SYMPTOM/CONDITION: Transaxle slips momentarily (engine RPM increases/flares) during light throttle 2-3 upshifts. DIAGNOSIS: Road test the vehicle. Accelerate at light throttle to achieve a 2-3 upshift at 18-22 MPH and listen for the engine to flare. If the engine flares during the 2-3 upshift, perform the Repair Procedure. PARTS REQUIRED: 1 (AR) 4669863 Bracket, Kickdown With Single Over Head Cam (SOHC) Engine 1 (AR) 4569864 Bracket, Kickdown With Double Over Head Cam (DOHC) Engine 1 (AR) 4659879 Valve Body 1 (AR) 4269649 Filter, Transaxle Oil AR 4798233 Fluid, Mopar Automatic Transmission Type 7176 REPAIR PROCEDURE: This bulletin involves adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and valve body and adjusting the throttle pressure cable. 1. Check the throttle pressure cable for proper adjustment (there should be no backlash) adjust if needed, use the following procedure while the engine is at normal operating temperature: A. Release the cross-lock on the throttle pressure cable assembly (pull the cross-lock up). Refer to Figure 1. B. To ensure proper adjustment, the cable must be free to slide all the way toward the engine (against its internal stop) after the cross-lock is released. Move the transaxle throttle control leveler fully clockwise (against its internal stop) and press the cross-lock down into the locked position. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Valve Cable/Linkage: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 3858 Adjustment is now complete and any throttle cable backlash has been automatically removed. Test the throttle pressure cable assembly for freedom of operation by moving the transaxle throttle control lever forward (counterclockwise). Then slowly release the lever to confirm it will return fully rearward (clockwise). No lubrication is required for the throttle cable system. C. Road test the vehicle to verify the flare condition is corrected. 2. If the flare condition persists, replace the kickdown bracket on the throttle body with the appropriate bracket specified in the Parts Required section of this bulletin. Then perform Step 1 again. 3. If the flare condition persists, replace the transaxle valve body (P/N 4659879), use the following procedure: A. Record the radio station presets and disconnect the battery cables. B. Pull the Power Distribution Center (PDC) up and out of its holding bracket. Set the PDC aside to gain clearance. C. Remove the battery from the vehicle and disconnect the cruise control, if equipped. D. Loosen the throttle pressure cable lever and gear shift cable lever pinch bolts. Refer to Figure 2. Remove both levers from their shafts and set aside. E. Raise the vehicle on an appropriate hoist. F. Clean the bottom of the transaxle. G. Remove the transaxle oil pan and properly dispose of the fluid. Be sure to remove all sealant from the mating surfaces. H. Remove the neutral start/back-up lamp switch. Refer to Figure 3. I. Remove and discard the transaxle oil filter. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Valve Cable/Linkage: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 3859 J. Remove the "E"-clip holding the parking rod to the valve body and separate the rod from the valve body. Refer to Figure 4. K. Remove the 7 bolts attaching the valve body to the transaxle and separate the valve body and governor tubes from the transaxle. Refer to Figure 5. L. Install the new valve body (P/N 4659879) and governor tubes to the transaxle, torque the 7 attaching bolts to 105 in. lbs. (12 Nm). M. Install the parking rod and secure with the "E"-clip previously removed. N. Install a new transaxle oil filter (P/N 4269649), torque the screws to 40 in. lbs. (5 Nm). 0. Install the neutral start/back-up lamp switch. P. Apply a 1/8 in. (3 mm) bead of Mopar Silicone Sealant (P/N 4318025) to the transaxle oil pan mounting flange. Attach the transaxle oil pan to the transaxle and torque the attaching bolts to 165 in. lbs. (19 Nm). Q. Install the throttle pressure cable lever and gear shift cable lever on their shafts and tighten their pinch bolts. R. Lower the vehicle and connect the cruise control, if equipped. S. Install the battery, PDC and connect the battery cables. T. Add 4 quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. U. Start the engine, and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. V. Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. W. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. X. Repeat Step 1 of this bulletin. Y. Program the previously recorded radio station presets, and set the clock. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Valve Cable/Linkage: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 3860 TIME ALLOWANCE: Labor Operation No: **21-75-32-93** Throttle Press. Cable, Adj. & Road Test 0.4 Hrs. FAILURE CODE: XX - Service Adjustment TIME ALLOWANCE: Labor Operation No: 21-75-32-91 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket Adj. Throttle Press. Cable & Road Test 1.0 Hrs. 21-75-32-92 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket & Valve Body Adj. Throttle Press. Cable & Road Test 2.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > Page 3861 Throttle Valve Cable/Linkage: Adjustments CABLE TYPE 1. Perform adjustment with engine at operating temperature. 2. Loosen cable mounting bracket lock screw. 3. Position mounting bracket with both alignment tabs touching transaxle cast surface. 4. Release cross-lock on cable assembly by pulling the cross-lock upward. To ensure proper adjustment, the cable must be free to slide all the way toward engine, against its stop, after the cross-lock is released. 5. Move transaxle throttle control lever fully clockwise against its internal stop, and press cross-lock downward into locked position. 6. Check cable for freedom of movement by moving throttle control lever. ROD TYPE 1. Ensure engine is at operating temperature. 2. Loosen adjustment swivel lock screw. Swivel must slide freely along flat end of throttle rod. 3. Hold transaxle throttle lever firmly toward engine, against its internal stop. Torque swivel lock screw to 8 Ft. lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Description and Operation > Torq Conv Clutch, No RPM Drop at Lockup Trouble Code Torque Converter Clutch: Description and Operation Torq Conv Clutch, No RPM Drop at Lockup Trouble Code Name of Code: Torn Conv Clutch. No RPM Drop at Lockup When Monitored: When all of the following steps are taken. 1. Run vehicle in the third gear with torque converter unlocked for about 10 seconds. 2. Apply heavy throttle until torque converter locks and then keep the torque converter locked for about 5 seconds. 3. Vehicle speed < 70 MPH during steps 1 and 2. 4. None of the following matured or maturing trouble code conditions: a. TCC solenoid circuit. b. Any cam (crank) related code c. Vehicle speed signal d. TPS signal e. TPS voltage low f. TPS voltage high Set Condition: Torque converter malfunctions that are detected are the torque converter not locking up property when desired, and the torque converter nut unlocking property when desired. A minimum amount of improvement in torque converter efficiency is expected after the torque converter is locked. This expected minimum improvement will not he seen when the torque converter is malfunctioning Two consecutive test failures over two trips will store the trouble code. Driving on mountainous terrain can cause this code to occur intermittently. Theory of Operation: The torque converter lockup system locks the crankshaft to the output shaft of the transmission when vehicle road load is stable and transmission is in third gear. This action reduces transmission oil heating, and improves fuel economy and thus emissions. The lockup system is controlled by the powertrain control module. Possible Causes: - Front wheel(s) size(s) is (are) bigger than 23.51" (185/65-R14, standard Neon wheel size), or smaller than 20.78" (T115/70-D14, Neon spare wheel size) - Low transmission oil level or pressure - Debris in transmission oil - Incorrect speedo gear for the front wheels - PTU solenoid not securely connected or stuck - Malfunctioning lock-up valve in transmission - Worn out friction material on friction disc in torque converter - Failed gear box, differential, or drive shaft contacts - Powertrain control module - Connector terminals/wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Description and Operation > Torq Conv Clutch, No RPM Drop at Lockup Trouble Code > Page 3866 Torque Converter Clutch: Description and Operation Torque Converter Clutch Solenoid Circuit Trouble Code Name of Code: Torque Converter Clutch Solenoid Circuit When Monitored: With the ignition key on. Set Condition: An open or shorted condition is detected in the torque converter clutch solenoid control circuit. Theory of Operation: The solenoid controls the operation of the converter clutch. A small current continuously senses the state of this circuit when the ignition key is turned on. Possible Causes: - Solenoid coil open or shorted - Fused ignition switch output circuit open - Solenoid control circuit open or shorted to ground Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications The Torque Converter Clutch Solenoid ( TCCS ) if good should measure between 30 to 50 OHMS. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations Torque Converter Clutch Solenoid: Component Locations The Torque Converter Clutch Solenoid is located on the Valve Body. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Component Locations > Page 3872 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3873 Transmission Control Solenoid Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3874 Torque Converter Clutch Solenoid: Testing and Inspection The Transmission Torque Converter Clutch Solenoid is diagnosed using powertrain diagnostic trouble codes ( DTC ). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Throttle Position Sensor Mounting Screws 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3878 Transmission Connections Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3881 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3882 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3883 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3884 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3885 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3886 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3887 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3888 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3889 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3890 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3891 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3892 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3893 Transmission Position Switch/Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3894 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3895 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3896 Rear Lighting (Part 1 Of 3) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Park/Neutral Position Switch Operation Transmission Position Switch/Sensor: Description and Operation Park/Neutral Position Switch Operation Fig. 20 Park/Neutral Switch OPERATION The park/neutral position switch is located on the automatic transaxle housing Fig. 20. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. CIRCUIT OPERATION When CLOSED the Transmission Range Switch (TRS) provides an input to the Powertrain Control Module (PCM) on circuit T41. This circuit connects to cavity 76 of the PCM connector. The T41 circuit is spliced and provides a ground path for the engine starter relay, and the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Park/Neutral Position Switch Operation > Page 3899 Transmission Position Switch/Sensor: Description and Operation Park/Neutral Switch Failure Trouble Code Name of Code: Park/Neutral Switch Failure (Sense Circuit) When Monitored: With the transmission in Park, Neutral, or Drive and not in limp-in mode. Set Condition: This code is set if the PCM detects an incorrect Park/Neutral switch state for a given mode of vehicle operation. Theory of Operation: The Transmission range Sensor (Park/Neutral position switch on 3 speed auto and all manual trans) is used to communicate whether or not the transmission is in Park or Neutral to the PCM. When the transmission is in Park or Neutral the Park/Neutral position switch sense circuit is grounded. Possible Causes: - Connector terminals and/or wires - Park/Neutral switch failure - Mechanical transmission problem - PCM failure Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 3900 Transmission Position Switch/Sensor: Testing and Inspection Park/Neutral Starting and Back-Up Lamp Switch 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 the switch, remove the wiring connector from the switch and test for continuity between the center pin of the switch and the transaxle case. Continuity should exist only when the transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 1. To test the switch, remove the wiring connector from the switch and test for continuity between the two outside pins. Continuity should only exist with the transaxle in the REVERSE position. 2. No continuity should exist from either pin to the transaxle case. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 3901 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Starting and Back-Up Lamp Switch Removal 1. Place a suitable container under the switch to catch fluid when switch is removed. 2. Unscrew switch from transaxle case allowing fluid to drain into container. 3. Move selector lever to PARK, then NEUTRAL position and inspect to see the switch operating lever fingers are centered in the switch opening. Installation 1. Crew the switch with a new seal into the transaxle case and tighten to 33 Nm (24 ft. lbs.). 2. Test switch with a test lamp. 3. Add fluid to transaxle to bring up to proper level. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations 31TH Transmission Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 212395A > Jan > 96 > A/T Slips on Light 2-3 Upshift Valve Body: Customer Interest A/T - Slips on Light 2-3 Upshift NO: 21-23-95 Rev. A GROUP: Transmission DATE: Jan. 26, 1996 SUBJECT: Transaxle Slips Momentarily During Light Throttle 2-3 Upshifts NOTE: This bulletin supersedes Technical Service Bulletin 21-23-95, dated Dec. 22, 1995, which should be removed from your files. A labor operation number is revised and highlighted with **asterisks**. MODELS: 1995 - 1996 (PL) Neon NOTE: This bulletin applies to vehicles equipped with a 31TH Transaxle. SYMPTOM/CONDITION: Transaxle slips momentarily (engine RPM increases/flares) during light throttle 2-3 upshifts. DIAGNOSIS: Road test the vehicle. Accelerate at light throttle to achieve a 2-3 upshift at 18-22 MPH and listen for the engine to flare. If the engine flares during the 2-3 upshift, perform the Repair Procedure. PARTS REQUIRED: 1 (AR) 4669863 Bracket, Kickdown With Single Over Head Cam (SOHC) Engine 1 (AR) 4569864 Bracket, Kickdown With Double Over Head Cam (DOHC) Engine 1 (AR) 4659879 Valve Body 1 (AR) 4269649 Filter, Transaxle Oil AR 4798233 Fluid, Mopar Automatic Transmission Type 7176 REPAIR PROCEDURE: This bulletin involves adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and valve body and adjusting the throttle pressure cable. 1. Check the throttle pressure cable for proper adjustment (there should be no backlash) adjust if needed, use the following procedure while the engine is at normal operating temperature: A. Release the cross-lock on the throttle pressure cable assembly (pull the cross-lock up). Refer to Figure 1. B. To ensure proper adjustment, the cable must be free to slide all the way toward the engine (against its internal stop) after the cross-lock is released. Move the transaxle throttle control leveler fully clockwise (against its internal stop) and press the cross-lock down into the locked position. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 212395A > Jan > 96 > A/T Slips on Light 2-3 Upshift > Page 3913 Adjustment is now complete and any throttle cable backlash has been automatically removed. Test the throttle pressure cable assembly for freedom of operation by moving the transaxle throttle control lever forward (counterclockwise). Then slowly release the lever to confirm it will return fully rearward (clockwise). No lubrication is required for the throttle cable system. C. Road test the vehicle to verify the flare condition is corrected. 2. If the flare condition persists, replace the kickdown bracket on the throttle body with the appropriate bracket specified in the Parts Required section of this bulletin. Then perform Step 1 again. 3. If the flare condition persists, replace the transaxle valve body (P/N 4659879), use the following procedure: A. Record the radio station presets and disconnect the battery cables. B. Pull the Power Distribution Center (PDC) up and out of its holding bracket. Set the PDC aside to gain clearance. C. Remove the battery from the vehicle and disconnect the cruise control, if equipped. D. Loosen the throttle pressure cable lever and gear shift cable lever pinch bolts. Refer to Figure 2. Remove both levers from their shafts and set aside. E. Raise the vehicle on an appropriate hoist. F. Clean the bottom of the transaxle. G. Remove the transaxle oil pan and properly dispose of the fluid. Be sure to remove all sealant from the mating surfaces. H. Remove the neutral start/back-up lamp switch. Refer to Figure 3. I. Remove and discard the transaxle oil filter. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 212395A > Jan > 96 > A/T Slips on Light 2-3 Upshift > Page 3914 J. Remove the "E"-clip holding the parking rod to the valve body and separate the rod from the valve body. Refer to Figure 4. K. Remove the 7 bolts attaching the valve body to the transaxle and separate the valve body and governor tubes from the transaxle. Refer to Figure 5. L. Install the new valve body (P/N 4659879) and governor tubes to the transaxle, torque the 7 attaching bolts to 105 in. lbs. (12 Nm). M. Install the parking rod and secure with the "E"-clip previously removed. N. Install a new transaxle oil filter (P/N 4269649), torque the screws to 40 in. lbs. (5 Nm). 0. Install the neutral start/back-up lamp switch. P. Apply a 1/8 in. (3 mm) bead of Mopar Silicone Sealant (P/N 4318025) to the transaxle oil pan mounting flange. Attach the transaxle oil pan to the transaxle and torque the attaching bolts to 165 in. lbs. (19 Nm). Q. Install the throttle pressure cable lever and gear shift cable lever on their shafts and tighten their pinch bolts. R. Lower the vehicle and connect the cruise control, if equipped. S. Install the battery, PDC and connect the battery cables. T. Add 4 quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. U. Start the engine, and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. V. Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. W. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. X. Repeat Step 1 of this bulletin. Y. Program the previously recorded radio station presets, and set the clock. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 212395A > Jan > 96 > A/T Slips on Light 2-3 Upshift > Page 3915 TIME ALLOWANCE: Labor Operation No: **21-75-32-93** Throttle Press. Cable, Adj. & Road Test 0.4 Hrs. FAILURE CODE: XX - Service Adjustment TIME ALLOWANCE: Labor Operation No: 21-75-32-91 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket Adj. Throttle Press. Cable & Road Test 1.0 Hrs. 21-75-32-92 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket & Valve Body Adj. Throttle Press. Cable & Road Test 2.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift Valve Body: All Technical Service Bulletins A/T - Slips on Light 2-3 Upshift NO: 21-23-95 Rev. A GROUP: Transmission DATE: Jan. 26, 1996 SUBJECT: Transaxle Slips Momentarily During Light Throttle 2-3 Upshifts NOTE: This bulletin supersedes Technical Service Bulletin 21-23-95, dated Dec. 22, 1995, which should be removed from your files. A labor operation number is revised and highlighted with **asterisks**. MODELS: 1995 - 1996 (PL) Neon NOTE: This bulletin applies to vehicles equipped with a 31TH Transaxle. SYMPTOM/CONDITION: Transaxle slips momentarily (engine RPM increases/flares) during light throttle 2-3 upshifts. DIAGNOSIS: Road test the vehicle. Accelerate at light throttle to achieve a 2-3 upshift at 18-22 MPH and listen for the engine to flare. If the engine flares during the 2-3 upshift, perform the Repair Procedure. PARTS REQUIRED: 1 (AR) 4669863 Bracket, Kickdown With Single Over Head Cam (SOHC) Engine 1 (AR) 4569864 Bracket, Kickdown With Double Over Head Cam (DOHC) Engine 1 (AR) 4659879 Valve Body 1 (AR) 4269649 Filter, Transaxle Oil AR 4798233 Fluid, Mopar Automatic Transmission Type 7176 REPAIR PROCEDURE: This bulletin involves adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and adjusting the throttle pressure cable; or replacing the kickdown bracket on the throttle body and valve body and adjusting the throttle pressure cable. 1. Check the throttle pressure cable for proper adjustment (there should be no backlash) adjust if needed, use the following procedure while the engine is at normal operating temperature: A. Release the cross-lock on the throttle pressure cable assembly (pull the cross-lock up). Refer to Figure 1. B. To ensure proper adjustment, the cable must be free to slide all the way toward the engine (against its internal stop) after the cross-lock is released. Move the transaxle throttle control leveler fully clockwise (against its internal stop) and press the cross-lock down into the locked position. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 3921 Adjustment is now complete and any throttle cable backlash has been automatically removed. Test the throttle pressure cable assembly for freedom of operation by moving the transaxle throttle control lever forward (counterclockwise). Then slowly release the lever to confirm it will return fully rearward (clockwise). No lubrication is required for the throttle cable system. C. Road test the vehicle to verify the flare condition is corrected. 2. If the flare condition persists, replace the kickdown bracket on the throttle body with the appropriate bracket specified in the Parts Required section of this bulletin. Then perform Step 1 again. 3. If the flare condition persists, replace the transaxle valve body (P/N 4659879), use the following procedure: A. Record the radio station presets and disconnect the battery cables. B. Pull the Power Distribution Center (PDC) up and out of its holding bracket. Set the PDC aside to gain clearance. C. Remove the battery from the vehicle and disconnect the cruise control, if equipped. D. Loosen the throttle pressure cable lever and gear shift cable lever pinch bolts. Refer to Figure 2. Remove both levers from their shafts and set aside. E. Raise the vehicle on an appropriate hoist. F. Clean the bottom of the transaxle. G. Remove the transaxle oil pan and properly dispose of the fluid. Be sure to remove all sealant from the mating surfaces. H. Remove the neutral start/back-up lamp switch. Refer to Figure 3. I. Remove and discard the transaxle oil filter. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 3922 J. Remove the "E"-clip holding the parking rod to the valve body and separate the rod from the valve body. Refer to Figure 4. K. Remove the 7 bolts attaching the valve body to the transaxle and separate the valve body and governor tubes from the transaxle. Refer to Figure 5. L. Install the new valve body (P/N 4659879) and governor tubes to the transaxle, torque the 7 attaching bolts to 105 in. lbs. (12 Nm). M. Install the parking rod and secure with the "E"-clip previously removed. N. Install a new transaxle oil filter (P/N 4269649), torque the screws to 40 in. lbs. (5 Nm). 0. Install the neutral start/back-up lamp switch. P. Apply a 1/8 in. (3 mm) bead of Mopar Silicone Sealant (P/N 4318025) to the transaxle oil pan mounting flange. Attach the transaxle oil pan to the transaxle and torque the attaching bolts to 165 in. lbs. (19 Nm). Q. Install the throttle pressure cable lever and gear shift cable lever on their shafts and tighten their pinch bolts. R. Lower the vehicle and connect the cruise control, if equipped. S. Install the battery, PDC and connect the battery cables. T. Add 4 quarts Mopar Automatic Transmission Fluid Type 7176 (P/N 4467721) through the dipstick opening. U. Start the engine, and allow to idle for a minimum of one minute. With the parking brake and the service brakes applied, move the gear selector lever momentarily to each gear position. Place the gear selector lever in either park or neutral. V. Check the transaxle fluid level and add an appropriate amount of transmission fluid to bring the level to 1/8 in. (3 mm) below the ADD mark on dipstick. W. Recheck the fluid level after the transaxle is at normal operating temperature. The level should be in the HOT range of the dipstick. X. Repeat Step 1 of this bulletin. Y. Program the previously recorded radio station presets, and set the clock. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 212395A > Jan > 96 > A/T - Slips on Light 2-3 Upshift > Page 3923 TIME ALLOWANCE: Labor Operation No: **21-75-32-93** Throttle Press. Cable, Adj. & Road Test 0.4 Hrs. FAILURE CODE: XX - Service Adjustment TIME ALLOWANCE: Labor Operation No: 21-75-32-91 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket Adj. Throttle Press. Cable & Road Test 1.0 Hrs. 21-75-32-92 Throttle Press. Cable, Adj. & Road Test, Replace Kickdown Bracket & Valve Body Adj. Throttle Press. Cable & Road Test 2.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Cleaning and Inspection Valve Body: Service and Repair Cleaning and Inspection CLEANING AND INSPECTION 1. Allow all parts to soak a few minutes in a suitable clean solvent. Wash thoroughly and blow dry with compressed air. Make sure all passages are clean and free from obstructions. 2. Inspect manual and throttle valve operating levers and shafts for being bent, worn or loose. If a lever is loose on its shaft, it should be replaced. Do not attempt to straighten bent levers. 3. Inspect all mating surfaces for burrs, nicks and scratches. Minor blemishes may be removed with crocus cloth, using only a very light pressure. Using a straightedge, inspect all mating surfaces for warpage or distortion. Slight distortion may be corrected, using a surface plate. Make sure all metering holes in steel plate are open. Using a pen light, inspect bores in valve body for scores scratches, pits and irregularities. 4. Inspect all valve springs for distortion and collapsed coils. Inspect all valves and plugs for burrs, nicks, and scores. Small nicks and scores may be removed with crocus cloth, providing extreme care is taken not to round off sharp edges. The sharpness of these edges is vitally important because it prevents foreign matter from lodging between valve and valve body, thus reducing possibility of sticking. Inspect all valves and plugs for freedom of operation in valve body bores. 5. When bores, valves, and plugs are clean and dry, the valves and plugs should fall freely in the bores. The valve body bores do not change dimensionally with use. Therefore, a valve body that was functioning properly when vehicle was new, will operate correctly if it is properly and thoroughly cleaned. There is no need to replace valve body unless it is damaged in handling. 6. Installation is the reverse of removal. Tighten all valve body screws to 5 Nm (40 in.lbs.). Fill transaxle to the proper level with ATF. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Cleaning and Inspection > Page 3926 Valve Body: Service and Repair Overhaul VALVE BODY RECONDITION NOTE: Prior to removing any transaxle subassemblies, plug all openings and thoroughly clean exterior of the unit, preferably by steam. Cleanliness through entire disassembly and assembly cannot be overemphasized. When disassembling, each part should be washed in a suitable solvent, then dried by compressed air. Do not wipe parts with shop towels. All mating surfaces in the transaxles are accurately machined; therefore, careful handling of all parts must be exercised to avoid nicks or burrs. Remove all old R.T.V. sealant before applying new R.T.V. sealant. Use only R.T.V. sealant when installing oil pan. Oil Pan Bolts Oil Pan 1. Remove or install neutral starting and back-up lamp switch. Oil Filter Screws Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Cleaning and Inspection > Page 3927 Oil Filter Parking Rod E-Clip Parking Rod Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Cleaning and Inspection > Page 3928 Valve Body Attaching Bolts Valve Body And Governor Tubes CAUTION: Do not clamp any portion of valve body or transfer plate in a vise. Any slight distortion of the aluminum body or transfer plate will result in sticking valves, excessive leakage, or both. When removing or installing valves or plugs, slide them in or out carefully. Do not use force. Detent Spring Attaching Screw And Spring WARNING: Tag all springs as they are removed for reassembly identification. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Cleaning and Inspection > Page 3929 Valve Body Screws Valve Body Screws Transfer Plate And Separator Plate Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Cleaning and Inspection > Page 3930 Steel Ball Locations Throttle Shaft E-Clip E-Clip, Washer And Oil Seal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Cleaning and Inspection > Page 3931 Manual Valve Lever And Assembly Throttle Valve Lever And Assembly Manual Valve Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Cleaning and Inspection > Page 3932 Pressure Regulator And Adjusting Screw Bracket Pressure Regulators And Manual Controls Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Cleaning and Inspection > Page 3933 Governor Plugs Pressure Regulator Valve Plugs Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Cleaning and Inspection > Page 3934 Shift And Shuttle Valve Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Adjustments Clutch Cable: Adjustments The clutch cable used on these vehicles incorporates a self adjusting mechanism within the cable outer housing at the pedal end of the cable. A preload spring is used to take up slack in the cable and to keep the release bearing tensional against the fingers of the clutch pressure plate. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Adjustments > Page 3939 Clutch Cable: Service and Repair CLUTCH CABLE The manual transaxle clutch release system has a unique self-adjusting mechanism to compensate for clutch disc wear. This adjuster mechanism is located within the clutch cable assembly. The preload spring maintains tension on the cable. This tension keeps the clutch release bearing continuously loaded against the fingers of the clutch cover assembly. REMOVAL 1. Pull up and remove Power Distribution Center. 2. Remove transaxle splash cover. 3. Pun back on clutch cable housing and disengage cable from housing. 4. Guide cable through slot in transaxle and disconnect cable from release lever. 5. Disconnect clutch cable from clutch pedal up- stop/spacer Note: Depressing the clutch pedal provides access to the clutch cable strand. Disconnect the cable end from the spacer by inserting a hooked tool into the clearance hole on the inboard side of the up-upstop/spacer. Now push the cable out- ward. Remove the upstop/spacer by inserting a screwdriver between the spacer and the shoulder of the pin on the clutch pedal. CAUTION: Do not pull on the clutch cable housing to move It from the dash panel. Damage to the cable if adjuster may occur. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Cable > Component Information > Adjustments > Page 3940 6. Cable End Removal:Use a slight twisting motion while grasping the grommet and body to remove the cable from the dash panel and clutch bracket. a screwdriver may be required to dislodge the cable grommet from the dash panel. Use caution to avoid damage to the cable grommet. INSTALLATION: 1. Using a slight twisting motion, insert the self adjuster mechanism end of the clutch cable through the dash panel hole and into the bracket 2. Seat the 8mm wide groove on the cable grommet in the dash panel. Make sure the self adjuster is firmly seated against the clutch bracket to ensure proper adjuster mechanism function. 3. Connect the clutch cable to the up-step/spacer. 4. Connect the up-stop/spacer to the clutch pedal. 5. Adjuster mechanism function check: With slight pressure, pull the clutch release lever end of the cable to draw the cable taut. Push the clutch cable housing toward the dash panel (With less than 15 lbs. of effort the cable housing should move 30-50mm). This indicates proper adjuster mechanism function. If the cable does not adjust, determine if the mechanism is properly seated on the bracket. 6. If the adjust mechanism functions properly, guide the cable through the slot in the transaxle housing. Connect cable to release lever, seating the cupped washer securely on lever tangs. 7. Pull back on clutch cable housing and insert into transaxle housing. 8. Reinstall splash cover and Power Distribution Center. Check clutch pedal position switch operation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Service and Repair Clutch Switch: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect electrical connector from switch. 3. Depress tabs on switch and push through mounting bracket. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal Axle Shaft: Service and Repair Removal The content of this article reflects the changes called out by TSB 26-01-95. REMOVAL CAUTION: - Boot sealing is vital to retain special lubricants and to prevent foreign contaminants from entering the C/V joint. Mishandling, such as allowing the assemblies to dangle unsupported, or pulling or pushing the ends can cut boots or damage C/V joints. During removal and installation procedures, always support both ends of the driveshaft to prevent damage. - The driveshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved on its wheels with a driveshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 183 Nm (135 ft. lbs.). This will ensure that the hub bearing cannot loosen. 1. Remove cotter pin, nut lock, and spring washer from the end of the outer C/V joint stub axle. 2. Loosen (but do not remove) stub axle-to-hub/bearing retaining nut. Loosen hub nut while vehicle is on the floor with the brakes applied. The front hub and driveshaft are splined together and retained by the hub nut. 3. Raise vehicle on jack stands or centered on a frame contact-type hoist. 4. Remove front tire and wheel assembly from the hub. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 3950 5. Remove front disc brake caliper assembly to steering knuckle bolts. 6. Remove disc brake caliper assembly from steering knuckle. Caliper is removed by first lifting bottom of caliper away from steering knuckle, and then removing top of caliper out from under steering knuckle. 7. Support brake caliper/adapter assembly using a wire hook, not by the brake flex hose. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 3951 8. Remove braking disc from front hub. 9. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod end using the following procedure: Hold tie rod end stud with a 11/32 socket while loosening and removing nut. 10. Remove the tie rod end stud from steering knuckle arm using Special Tool MB-990630, or equivalent. 11. Remove nut and bolt retaining ball joint stud into steering knuckle. NOTE: Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get damaged. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 3952 12. Separate ball joint stud from steering knuckle by prying down on lower control arm. NOTE: Care must be taken not to separate the inner ON joint during this operation. Do not allow driveshaft to hang by inner ON joint, driveshaft must be supported. 13. Pull steering knuckle assembly out and away from outer C/V joint of the driveshaft assembly. 14. Support outer end of the driveshaft assembly. NOTE: Removal of the inner tripod joints is made easier if you apply outward pressure on the joint as you strike the punch with a hammer. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 3953 15. Remove the inner tripod joints from the side gears of the transaxle using a punch to dislodge the inner tripod joint retaining ring from the transaxle side gear. If removing the right side inner tripod joint, position the punch against the inner tripod joint. Strike the punch sharply with a hammer to dislodge the right inner joint from the side gear. If removing the left side inner tripod joint, position the punch in the groove of the inner tripod joint. Strike the punch sharply with a hammer to dislodge the left inner tripod joint from the side gear. 16. Hold inner tripod joint and interconnecting shaft of driveshaft assembly. Remove inner tripod joint from transaxle by pulling it straight out of transaxle side gear and transaxle oil seal. When removing tripod joint, do not let spline or snap ring drag across sealing lip of the transaxle to tripod joint oil seal. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 3954 Axle Shaft: Service and Repair Installation The content of this article reflects the changes called out by TSB 26-01-95. INSTALLATION CAUTION: The driveshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved an its wheels with a driveshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 183 Nm (135 ft lbs.). This will ensure that the hub bearing cannot loosen. 1. Thoroughly clean spline and oil seal sealing surface, on tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean transmission lubricant. 2. Holding driveshaft assembly by tripod joint and interconnecting shaft, install Tripod joint into transaxle side gear as far as possible by hand. 3. Carefully align tripod joint with transaxle side gears. Then grasp driveshaft interconnecting shaft and push tripod joint into transaxle side gear until fully seated. Test that snap ring is fully engaged with side gear by attempting to remove tripod joint from transaxle by hand. If snap ring is fully engaged with side gear tripod joint will not be removable by hand. 4. Clean all debris and moisture out of steering knuckle. 5. Ensure that front of outer C/V joint, which fits into steering knuckle, is free of debris and moisture before assembling into steering knuckle. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 3955 6. Slide driveshaft back into front hub. Install steering knuckle onto the ball joint stud. 7. Install a NEW steering knuckle to ball joint stud clamping bolt and nut. Tighten the nut and bolt to 95 Nm (70 ft. lbs.). 8. Install tie rod end into steering knuckle. Start tie rod end to steering knuckle nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle nut. Then, using a crowfoot and 11/32 socket, tighten tie rod end nut to 61 Nm (45 ft. lbs.). 9. Install braking disc back on hub and bearing assembly. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 3956 10. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding top of caliper under top abutment on steering knuckle. Then installing bottom of caliper against bottom abutment of steering knuckle. 11. Install caliper assembly to steering knuckle bolts. Tighten to 31 Nm (23 ft. lbs.). 12. Clean all foreign matter from threads of outer C/V joint stub axle. Install hub nut and washer onto the threads of the stub axle and tighten nut. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 3957 13. With vehicle brakes applied to keep axle shaft from turning, tighten hub nut to 183 Nm (135 ft. lbs.). 14. Install spring washer, hub nut lock and new cotter pin on outer C/V joint stub axle. Wrap the cotter pin prongs tightly around the hub nut lock. 15. Install front wheel and tire assembly. Install front wheel lug nuts and tighten to 135 Nm (100 ft. lbs.). 16. Check for correct fluid level in transaxle assembly. 17. Lower vehicle. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal > Page 3958 Axle Shaft: Service and Repair Overhaul NOTE: The only service that is to be performed on the driveshaft assemblies is the replacement of the driveshaft seal boots. If any failure of internal driveshaft components is diagnosed during a vehicle road test or disassembly of the driveshaft, the driveshaft will need to be replaced as an assembly. NOTE: Lubricant requirements and quantities are different for inner joints than for outer joints. Use only the recommended lubricants in the required quantities when servicing driveshaft assemblies. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair Constant Velocity Joint Boot: Service and Repair Removal 1. Remove driveshaft as outlined under Driveshaft Replacement. 2. Remove inner joint boot clamps then slide boot down interconnecting shaft. 3. Remove interconnecting shaft and spider assembly out of joint housing. 4. Remove snap ring then spider assembly from interconnecting shaft using a brass drift if necessary. Do not hit the outer tripod bearings when removing spider assembly. 5. Remove joint boot from interconnecting shaft. 6. Clean and inspect spider assembly, tripod joint housing and interconnecting shaft for any signs of excessive wear. If any excessive wear is present, replacement of entire driveshaft will be necessary. Installation Two different types of boots are used on these models, a high temperature, soft and pliable type and a normal temperature, stiff and rigid type. The replacement boot must be the same type which was removed. 1. Install new boot clamps and boot onto interconnecting shaft. 2. Install spider assembly onto interconnecting shaft then the retaining snap ring. Ensure retaining snap ring is fully installed. 3. Distribute 1/2 the amount of grease provided in boot service package into tripod housing and the remaining amount into boot. 4. Install spider assembly into tripod housing. 5. Position boot over boot retaining grove on interconnecting shaft and install boot retaining clamp using Crimper tool No. C-4975 or equivalent. 6. Position boot into tripod housing retaining groove. Fig. 4 Driveshaft Removal, 90-91 Colt Wagon And Colt Vista 7. Prior to crimping boot clamp, the inner tripod joint must be at correct stroke position as shown. This ensures proper amount of air is inside sealing boot before clamp is crimped. Failure to perform this step will result in inner boot failure. 8. After adjusting stroke position, crimp boot clamp using Crimper tool. 9. Install driveshaft as outlined under "Driveshaft, Replace." Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 DISASSEMBLE All steps of the hub bearing removal from steering knuckle must be done using a hydraulic arbor press. 1. Install bearing splitter tool No. P334, or equivalent, on steering knuckle and hub/bearing assembly to support steering knuckle when pressing out bearing. Hub, Bearing & Steering Knuckle Supported For Removal Of Hub 2. Position steering knuckle and hub/bearing assembly in vise, support by splitter tool No. P334, or equivalent. 3. Position driver tool No. 6644-2, or equivalent, on small end of hub, then press hub from bearing. The one bearing race may come out with hub when hub is removed from bearing. Hub Bearing Removal 4. Remove bearing splitter from steering knuckle, then place steering knuckle is press supported by press blocks. 5. Place bearing driver tool No. MB-990799, or equivalent, on outer race of hub bearing, then press hub bearing completely out of steering knuckle. 6. Install bearing splitter tool No. P334, or equivalent, on hub so it is between flange of hub and bearing race remaining on hub. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3966 Hub Bearing Race Removal 7. Install assembly into press, then place driver tool on end of hub and press hub out of hub bearing race. ASSEMBLE 1. Install new bearing into bore of steering knuckle so it is square with bore, then place steering knuckle in press with receiver tool No. C-4698-2, or equivalent, supporting steering knuckle. 2. Place driver tool No. 5052, or equivalent, on outer race of hub, then press hub bearing into steering knuckle until it is fully bottom in bearing bore of steering knuckle. 3. Install hub bearing retaining snap ring into groove in hub bearing bore of steering knuckle. Ensure snap ring is fully seated. Hub Bearing Installation 4. Place steering knuckle with hub bearing installed in press with receiver tool No. MB-990799, or equivalent, supporting inner race of hub bearing. 5. Place hub into hub bearing ensuring it is square with bearing. 6. Place driver tool No. 6522, or equivalent, on front face of hub, then press hub into bearing until it bottoms in hub bearing. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 3967 Wheel Bearing: Service and Repair Rear With Rear Disc Brakes The rear hub and bearing are serviced as an assembly. 1. Raise and support vehicle, then remove wheel. 2. Remove caliper and disc. 3. Remove the hub retaining nut, then the hub and bearing assembly. 4. Reverse procedure to install. Tighten nuts and bolts to specifications. With Rear Drum Brakes The rear hub and bearing are serviced as an assembly. 1. Raise and support vehicle, then remove wheel. 2. Remove drum. 3. Remove the hub retaining nut, then the hub and bearing assembly. 4. Reverse procedure to install. Tighten nuts and bolts to specifications. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 3977 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 3983 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 3984 Axle Nut: Specifications Front Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 183 Nm (135 ft. lbs.) Rear Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 217 Nm (160 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Torque Torque Flex Plate to Crankshaft 70 ft lbs Flex Plate to Torque Conveter 50 ft lbs Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation CIRCUIT OPERATION The PRNDL lamp receives power on the E2 circuit from the 4 Amp fuse located in the fuse block in cavity 12. The fuse receives power from the headlamp switch. Circuit E2 also powers the ash receiver lamp. When the headlamp switch is moved to the PARK or ON position, current flows through the fuse to the PRNDL lamp. The ground for the lamp is supplied on the Z3 circuit, and terminates at the instrument panel left center support. This circuit is also spliced in with the ash receiver lamp, the ignition switch lamp, and the glove box lamp. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid .............................................................................................................................. .......................................................... 2.1L (4.4 Pints) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 3998 Fluid - M/T: Fluid Type Specifications Transmission Fluid .............................................................................................................................. ............................................ MOPAR Type MS 9417 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft Bearing, M/T > Component Information > Technical Service Bulletins > M/T - Output Bearing Service Procedure Revision Output Shaft Bearing: Technical Service Bulletins M/T - Output Bearing Service Procedure Revision NUMBER: 26-04-96J GROUP: Miscellaneous DATE: Apr. 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1996 Neon - Publication Number 81-370-6025 DESCRIPTION OF CHANGES Changes to the transaxle output bearing procedure Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft Bearing, M/T > Component Information > Technical Service Bulletins > M/T - Output Bearing Service Procedure Revision > Page 4003 21-30 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Adjustments Shift Cable: Adjustments The gearshift selector cable is not adjustable. If adjustment is required, only the crossover cable may be adjusted. 1. Remove gearshift console from vehicle. Gearshift Crossover Cable Adjustment 2. Loosen crossover cable adjustment screw. Crossover Lever Attachment To Transaxle 3. Using a 1/4 inch drill bit or suitable equivalent, pin crossover cable lever to transaxle. Ensure drill bit engages through crossover lever into transaxle case at least one half inch. 4. Ensure shift lever is in the spring loaded neutral position. If necessary, move lever forward and back, then allow lever to fall into it's natural neutral position. 5. Without allowing movement in either cable or lever, hand tighten crossover cable adjustment screw, then tighten screw to specifications. 6. Remove pin from transaxle crossover lever, then check transaxle shift functions. 7. Install gearshift console. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Adjustments > Page 4008 Shift Cable: Service and Repair NOTE: Use this procedure if either of the shift cables require replacement. REMOVAL AND INSTALLATION 1. Disconnect Power Distribution Center from battery tray and set aside. 2. Remove air cleaner inlet horn. 3. Remove battery and battery tray. Shift Cable Removal 4. Disconnect gear shift cable ends from transaxle shift levers. CAUTION: Pry up with equal force on both sides of shifter cable isolator bushings to avoid damaging cable isolator bushings. 5. Remove cable to bracket retaining clips at transaxle. CAUTION: It is recommended that new cable retaining clips be used for reinstallation. 6. Pull cables up out of transaxle bracket. 7. Remove console from vehicle. Cable Retaining Clips 8. Remove floor pan grommet retaining nuts. 9. Remove cable retaining clips at shifter. CAUTION: It is recommended that new cable retaining clips be used for reinstallation. 10. Disconnect shift cables from shifter. Pry with equal force on both sides of shifter cable isolator bushings to avoid damaging bushings. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Adjustments > Page 4009 Shift Cable Floor Grommet 11. Lift vehicle on hoist. Remove self tapping screws securing grommet plate to underbody heat shield and floor pan. 12. Detach cables from cable support clip in tunnel above exhaust catalyst. 13. Remove shift cables from vehicle. To install, reverse removal procedure. After cables have been replaced, cable adjustment should be checked. CAUTION: Only the crossover cable is adjustable. The selector cable does not have any adjustment capabilities. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Throttle Position Sensor Mounting Screws 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4020 Transmission Connections Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4023 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4024 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4025 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4026 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4027 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4028 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4029 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4030 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4031 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4032 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4033 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4034 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4035 Transmission Position Switch/Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4036 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4037 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4038 Rear Lighting (Part 1 Of 3) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Park/Neutral Position Switch Operation Transmission Position Switch/Sensor: Description and Operation Park/Neutral Position Switch Operation Fig. 20 Park/Neutral Switch OPERATION The park/neutral position switch is located on the automatic transaxle housing Fig. 20. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. CIRCUIT OPERATION When CLOSED the Transmission Range Switch (TRS) provides an input to the Powertrain Control Module (PCM) on circuit T41. This circuit connects to cavity 76 of the PCM connector. The T41 circuit is spliced and provides a ground path for the engine starter relay, and the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Park/Neutral Position Switch Operation > Page 4041 Transmission Position Switch/Sensor: Description and Operation Park/Neutral Switch Failure Trouble Code Name of Code: Park/Neutral Switch Failure (Sense Circuit) When Monitored: With the transmission in Park, Neutral, or Drive and not in limp-in mode. Set Condition: This code is set if the PCM detects an incorrect Park/Neutral switch state for a given mode of vehicle operation. Theory of Operation: The Transmission range Sensor (Park/Neutral position switch on 3 speed auto and all manual trans) is used to communicate whether or not the transmission is in Park or Neutral to the PCM. When the transmission is in Park or Neutral the Park/Neutral position switch sense circuit is grounded. Possible Causes: - Connector terminals and/or wires - Park/Neutral switch failure - Mechanical transmission problem - PCM failure Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Page 4042 Transmission Position Switch/Sensor: Testing and Inspection Park/Neutral Starting and Back-Up Lamp Switch 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 the switch, remove the wiring connector from the switch and test for continuity between the center pin of the switch and the transaxle case. Continuity should exist only when the transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 1. To test the switch, remove the wiring connector from the switch and test for continuity between the two outside pins. Continuity should only exist with the transaxle in the REVERSE position. 2. No continuity should exist from either pin to the transaxle case. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Page 4043 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Starting and Back-Up Lamp Switch Removal 1. Place a suitable container under the switch to catch fluid when switch is removed. 2. Unscrew switch from transaxle case allowing fluid to drain into container. 3. Move selector lever to PARK, then NEUTRAL position and inspect to see the switch operating lever fingers are centered in the switch opening. Installation 1. Crew the switch with a new seal into the transaxle case and tighten to 33 Nm (24 ft. lbs.). 2. Test switch with a test lamp. 3. Add fluid to transaxle to bring up to proper level. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Specifications Torque Converter Clutch Solenoid: Specifications The Torque Converter Clutch Solenoid ( TCCS ) if good should measure between 30 to 50 OHMS. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Component Locations Torque Converter Clutch Solenoid: Component Locations The Torque Converter Clutch Solenoid is located on the Valve Body. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Component Locations > Page 4052 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 4053 Transmission Control Solenoid Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 4054 Torque Converter Clutch Solenoid: Testing and Inspection The Transmission Torque Converter Clutch Solenoid is diagnosed using powertrain diagnostic trouble codes ( DTC ). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation CIRCUIT OPERATION The PRNDL lamp receives power on the E2 circuit from the 4 Amp fuse located in the fuse block in cavity 12. The fuse receives power from the headlamp switch. Circuit E2 also powers the ash receiver lamp. When the headlamp switch is moved to the PARK or ON position, current flows through the fuse to the PRNDL lamp. The ground for the lamp is supplied on the Z3 circuit, and terminates at the instrument panel left center support. This circuit is also spliced in with the ash receiver lamp, the ignition switch lamp, and the glove box lamp. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications Throttle Position Sensor Mounting Screws 2 Nm (20 in lb) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4070 Transmission Connections Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4073 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4074 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4075 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4076 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4077 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4078 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4079 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4080 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4081 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4082 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4083 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4084 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4085 Transmission Position Switch/Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4086 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4087 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Diagrams > Diagram Information and Instructions > Page 4088 Rear Lighting (Part 1 Of 3) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Park/Neutral Position Switch Operation Transmission Position Switch/Sensor: Description and Operation Park/Neutral Position Switch Operation Fig. 20 Park/Neutral Switch OPERATION The park/neutral position switch is located on the automatic transaxle housing Fig. 20. Manual transaxles do not use park/neutral switches. The switch provides an input to the PCM to indicate whether the automatic transaxle is in Park/Neutral, or a drive gear selection. This input is used to determine idle speed (varying with gear selection) and ignition timing advance. The park/neutral input is also used to cancel vehicle speed control. The park/neutral switch is sometimes referred to as the neutral safety switch. CIRCUIT OPERATION When CLOSED the Transmission Range Switch (TRS) provides an input to the Powertrain Control Module (PCM) on circuit T41. This circuit connects to cavity 76 of the PCM connector. The T41 circuit is spliced and provides a ground path for the engine starter relay, and the Transmission Control Module (TCM). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Park/Neutral Position Switch Operation > Page 4091 Transmission Position Switch/Sensor: Description and Operation Park/Neutral Switch Failure Trouble Code Name of Code: Park/Neutral Switch Failure (Sense Circuit) When Monitored: With the transmission in Park, Neutral, or Drive and not in limp-in mode. Set Condition: This code is set if the PCM detects an incorrect Park/Neutral switch state for a given mode of vehicle operation. Theory of Operation: The Transmission range Sensor (Park/Neutral position switch on 3 speed auto and all manual trans) is used to communicate whether or not the transmission is in Park or Neutral to the PCM. When the transmission is in Park or Neutral the Park/Neutral position switch sense circuit is grounded. Possible Causes: - Connector terminals and/or wires - Park/Neutral switch failure - Mechanical transmission problem - PCM failure Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Page 4092 Transmission Position Switch/Sensor: Testing and Inspection Park/Neutral Starting and Back-Up Lamp Switch 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 the switch, remove the wiring connector from the switch and test for continuity between the center pin of the switch and the transaxle case. Continuity should exist only when the transaxle is in PARK or NEUTRAL. 2. Check gearshift cable adjustment before replacing a switch that tests bad. The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 1. To test the switch, remove the wiring connector from the switch and test for continuity between the two outside pins. Continuity should only exist with the transaxle in the REVERSE position. 2. No continuity should exist from either pin to the transaxle case. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 > Description and Operation > Page 4093 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Starting and Back-Up Lamp Switch Removal 1. Place a suitable container under the switch to catch fluid when switch is removed. 2. Unscrew switch from transaxle case allowing fluid to drain into container. 3. Move selector lever to PARK, then NEUTRAL position and inspect to see the switch operating lever fingers are centered in the switch opening. Installation 1. Crew the switch with a new seal into the transaxle case and tighten to 33 Nm (24 ft. lbs.). 2. Test switch with a test lamp. 3. Add fluid to transaxle to bring up to proper level. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation The Antilock Brake System (ABS) warning lamp located on the instrument cluster will turn on when the CAB detects a condition which results in a shutdown of the ABS function. The ABS warning lamp will turn on for approximately four-five seconds after the ignition key is switched to the ON position. During this time the CAB runs a system self test. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Description and Operation ABS Main Relay: Description and Operation CIRCUIT OPERATION The system relay is used for the operation of the ABS system. Power for the relay is supplied on the B57 circuit from cavity 57 of the Controller Anti Lock Brake (CAB). Ground for the relay is on the Z1 circuit. This ground is spliced in with the pump motor and terminates at the left headlamp ground. When the system is operating normally power for the contact side of the relay is supplied from the CAB on the B57 circuit. It passes through the relay to the Z1 ground and terminates at the left headlamp ground. If a problem is detected in the system, the contact side of the relay switches from the Z1 to the F12 circuit. This causes the ABS warning lamp in the instrument cluster to illuminate. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump Relay > Component Information > Description and Operation Brake Fluid Pump Relay: Description and Operation CIRCUIT OPERATION The ABS pump motor relay controls when the pump motor runs. Power for the coil side of the relay is supplied from cavity 47 of the Controller Anti Lock Brake (CAB) on the B47 circuit. This circuit also supplies voltage for the contact side of the system relay The ground side of the coil is controlled by the B116 circuit. Circuit B116 connects to cavity 16 of the CAB connector. Circuit B120 from cavity 20 of the CAB connector powers the ABS pump motor. This circuit is also used as an input to the CAB for pump motor monitoring. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Description and Operation Braking Sensor/Switch: Description and Operation CIRCUIT OPERATION Circuit L50 is an input to the Controller Anti Lock Brake (CAB). The L50 connects to cavity 13 of the CAB connector. Circuit L50 is spliced in with the stop lamps and is used to provide the CAB with information on when the brakes are being applied. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations Data Link Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > Page 4111 Data Link Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Testing and Inspection > Circuit Operation Diagnostic Connector - ABS: Testing and Inspection Circuit Operation CIRCUIT OPERATION Circuit D21 is used for diagnostics of a fault with the ABS system. It is spliced in with the Powertrain Control Module (PCM) circuits and used as an output from the Controller Anti Lock Brake (CAB). Circuit D21 connects to cavity 51 of the CAB connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Testing and Inspection > Circuit Operation > Page 4114 Diagnostic Connector - ABS: Testing and Inspection Helpful Information - Check the 15 Amp fuse located in cavity 10 of the fuse block. - Check the 40 Amp fuse located in the PDC. - Check for a good ground at the left headlamp ground. - Check the case ground on the CAB Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation Electronic Brake Control Module: Description and Operation Fig 1 Controller Anti-Lock Brake System (CAB) Fig 2 Controller Anti-Lock System (CAB) The Controller, Antilock Brake (CAB) located under the lefthand side of the instrument panel is a microprocessor device which monitors wheel speed and controls Antilock Brake System (ABS). The CAB monitors the speed of each wheel through the signals generated at the wheel speed sensors to determine if any wheel is beginning to lock. If any wheel lock is detected, the CAB commands the Hydraulic Control Unit (HCU) to modulate pressure to some or all of the hydraulic circuits. The CAB constantly monitors the ABS system for proper operation. If the CAB detects a fault, it will turn on the ABS warning lamp and disable the ABS braking system. The CAB contains a self-diagnostic program which will store system faults in a diagnostic program memory. There are multiple fault messages which may be stored in the CAB memory and can be displayed with a DRB or equivalent scan tool. These faults will remain in the CAB memory even after the ignition has been turned off. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > Page 4118 Electronic Brake Control Module: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect wiring harness 60-way connector from CAB. 3. Remove two CAB bracket to driver's side cowl mounting nuts. 4. Remove CAB from vehicle. 5. Reverse procedure to install, torque 60-way connector retaining bolt to 38 inch lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > Hydraulic Control Unit (HCU) Hydraulic Control Unit: Description and Operation Hydraulic Control Unit (HCU) The Hydraulic Control Unit (HCU) is located under the master cylinder. The HCU contains the following components for controlling brakes during ABS braking; four decay valves, four shuttle valves, two fluid sumps, a pump/motor and a relay box. Also attached to the HCU are rear brake proportioning valves and the six hydraulic tubes. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > Hydraulic Control Unit (HCU) > Page 4123 Hydraulic Control Unit: Description and Operation Hydraulic Modulator Circuit Operation CIRCUIT OPERATION The hydraulic modulator is used for the controlling of the brake system pressure to the wheels. The modulator is made up of four solenoids. Circuits involved are, B142 for the left front wheel, B143 for the right front wheel, B146 for the left rear wheel, and B148 for the right rear wheel. The solenoids use a common ground on the Z1 circuit. There are two Z1 circuits from the modulator. Both of these grounds terminate at the left headlamp ground, and are spliced in with the Anti-lock Brakes System (ABS) pump motor and the ABS system relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > Page 4124 Hydraulic Control Unit: Service and Repair The content of this article reflects the changes called out by TSB 05-07-94. REMOVAL 1. Disconnect battery ground cable and isolate cable. 2. Disconnect brake fluid level sensor electrical connector at base of master cylinder. 3. Disconnect primary and secondary brake tubes from master cylinder. Install plugs into master cylinder brake tube outlets. 4. Use a suitable brake cleaner to clean area where master cylinder attaches to power booster. 5. Pump brake pedal until it is firm. This will pump down the vacuum inside the power booster and prevent the booster from sucking in any contamination when removing the master cylinder. 6. Remove master cylinder to power booster retaining nuts, then slide master cylinder straight out. 7. Disconnect 6-way electrical connector from Hydraulic Control Unit (HCU) wiring harness and 10-way electrical connector from HCU relay box. 8. Remove primary and secondary master cylinder brake tubes from HCU. 9. Remove remaining brake tubes from proportioning valves and HCU outlet ports. 10. Raise and support vehicle. 11. Remove two bolts attaching HCU mounting bracket to side of front of frame rail. 12. Lower vehicle and remove bolts attaching HCU mounting bracket to top of frame rail. 13. Remove HCU and mounting bracket as an assembly from vehicle. INSTALLATION 1. Install HCU and mounting bracket as an assembly, on left frame rail of vehicle, aligning tabs on mounting bracket with holes in frame rail. 2. Install and loosely tighten bolt attaching HCU mounting bracket to top of frame rail. 3. Raise and support vehicle. 4. Install two bolts attaching HCU mounting bracket to side of front frame rail. Torque bolts to 16 ft. lbs. 5. Lower vehicle and torque bolt attaching HCU mounting bracket to top of frame rail to 9 ft. lbs. 6. Install four chassis brake tubes to HCU proportioning valves and outlet ports, torque brake tube nuts to 12 ft. lbs. 7. Install primary and secondary brake tubes from master cylinder onto HCU, then hand tighten tube nuts. 8. Connect electrical connectors to HCU. Fig 61 Power Brake Booster Vacuum Seal Removal 9. Using a small screwdriver, carefully remove vacuum seal from front of power brake booster. Do not attempt to pry seal out of master cylinder by inserting a tool between seal and power brake vacuum booster. 10. Remove old vacuum seal from master cylinder, if seal came out of power brake vacuum booster when master cylinder was removed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > Page 4125 Fig 62 Power Brake Booster Vacuum Seal Installation 11. Lubricate master cylinder push rod with Mopar Silicone Dielectric Compound - NO Substitutes. Then install new vacuum seal onto master cylinder push rod as shown. 12. Position master cylinder on studs of power brake booster, aligning push rods of power brake booster and master cylinder. 13. Install two master cylinder mounting nuts and torque to 21 ft. lbs. 14. Connect primary and secondary tubes to master cylinder and HCU. Torque brake tube nuts at master cylinder to 12 ft. lbs. and torque brake tube nuts at HCU to 15 ft. lbs. 15. Connect brake fluid level sensor electrical connector. 16. Bleed brake system as described in Hydraulic System/Service and Repair/Brake System Bleed procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4130 39 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4131 43 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4132 45 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4133 47 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4134 51 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4135 55 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4136 57 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4137 59 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4138 63 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4139 67 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4140 69 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4141 71 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4142 173 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4143 177 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4144 179 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4145 181 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4146 187 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4147 191 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4148 193 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4149 195 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4150 201 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4151 205 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4152 207 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4153 209 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4154 256 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 4155 Wheel Speed Sensor: Description and Operation OPERATION One wheel speed sensor (WSS) is located at each wheel and sends an AC signal to the Controller, Antilock Brake (CAB). The voltage is generated by magnetic induction when a tooth sensor ring passes by a stationary magnetic sensor. The CAB then converts the AC signal into digital signals for each wheel. The four wheel speed sensors are serviced individually. CIRCUIT OPERATION There are four wheel speed sensors, one at each wheel. The sensors use a tone wheel to determine wheel speed. Input to the Controller Anti Lock Brake (CAB) is done on the following circuits. All of these circuits are a twisted pair. B8 and B9 for the left front wheel (cavity 8 and cavity 9). B6 and B7 for the right front wheel (cavity 6 and cavity 7). B3 and B4 for the left rear wheel (cavity 3 and cavity 4). B1 and B2 for the right rear wheel (cavity 1 and cavity 2). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 4156 Wheel Speed Sensor: Service and Repair Inspect tone wheel for missing or broken teeth, ensure tone wheel has not made contact with wheel speed sensor. Replace tone wheel if runout exceeds 0.010 inch. FRONT 1. Raise and support vehicle, then remove tire and wheel assembly. 2. Remove grommet retaining clip attaching screw, then pull sensor assembly grommet from fender shield. 3. Unplug speed sensor connector from vehicle wiring harness connector, then remove speed sensor cable routing bracket from front strut assembly. 4. Remove screw attaching speed sensor head to steering knuckle, then sensor from steering knuckle. Do not use pliers on sensor head, use a hammer and punch to tap edge of sensor ear, rocking sensor side to side until free. 5. Reverse procedure to install noting the following: a. Coat sensor head with high temperature multi-purpose E.P grease. b. Torque speed sensor head to 60 inch lbs. c. In two steps, torque wheel lug nuts to 95 ft. lbs. REAR 1. Disconnect battery ground cable. 2. Raise and support vehicle. 3. Remove rear tire and wheel assembly. 4. Remove clip attaching speed sensor cable connector to vehicle body, then disconnect speed sensor cable connector from vehicle wiring harness. 5. Remove speed sensor cable routing bracket from rear brake flex hose mounting bracket. 6. Remove speed sensor cable from routing clips on rear brake flex hose and chassis brake tube. 7. Remove speed sensor attaching bolt from drum brake support or disc brake adapter. 8. Remove speed sensor cable routing bracket attaching bolt from rear strut assembly. 9. Remove sensor head from support plate or adapter. Do not use pliers on sensor head, use a hammer and punch to tap edge of sensor ear, rocking sensor side to side until free. 10. Reverse procedure to install, torque speed sensor attaching bolt to 60 inch lbs. and wheel lug nuts to 80-110 ft. lbs.. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Wheel Bleed Sequence LR,RF,RR,LF Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding Brake Bleeding: Service and Repair About Brake System Bleeding BASE BRAKE SYSTEM BLEEDING Bleeding the hydraulic brake system is necessary if air has entered the system. A few causes for this condition are low fluid level, a hydraulic fluid leak, a hydraulic line is opened, or replacement of a hydraulic system component. Symptoms can be noted by an improper or loss of brake operation, and/or a low or spongy brake pedal. Flushing the hydraulic brake system is necessary if contaminants are found in the hydraulic system. A few causes for hydraulic system contamination are moisture, age of hydraulic system parts and fluid, or improper fluid used in the system. Symptoms can be noted by an improper or loss of brake operation, swollen and deteriorated cups and other rubber parts, and/or a discoloration of the brake fluid. The hydraulic fluid is bled or flushed from the system through bleeder valves located on the calipers, wheel cylinders, and some master cylinders. When bleeding the hydraulic brake system, use only specified brake fluid, and never reuse old brake fluid removed from the system. PRESSURE BLEEDING Pressure bleeding is recommended for all hydraulic brake systems. It is the fastest method because the master cylinder is automatically fed brake fluid from the pressure bleeder reservoir, and no pedal pumping is needed so only one person is required to perform the procedure. However, if pressure bleeding equipment is not available, the hydraulic system may be bled as described under "Manual Bleed." When pressure bleeding, to prevent air from getting into the hydraulic system, do not shake the pressure tank. Set the tank in the required location, bring the air hose to the tank, and do not move it during the bleeding operation. The tank should be kept at least one-third full. The bleeder valve should be opened at least one full turn, and intermittently closed at about four-second intervals. This gives a whirling action to fluid in the hydraulic system, and helps expel the air. Refer to Hydraulic Brake System/Specifications for proper wheel bleeding sequence. PRECAUTIONS Normal pressure from the pressure bleeder should not be greater than about 35 PSI. On vehicles equipped with plastic reservoirs, do not exceed 25 PSI bleeding pressure. On models with hold-off valves contained in the combination valve, the valve stem on the outside of the combination valve must be held in position during bleeding using valve holding tool No. C-4121, or equivalent. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 4162 Brake Bleeding: Service and Repair Base Brake System Bleeding On models with power brakes, bleed the hydraulic system without the engine running. Reduce vacuum in the power unit to zero by pumping the brake pedal several times with the engine Off. 1. Ensure master cylinder reservoir is full. 2. Raise and support vehicle. 3. Position a drain pan under the wheel being bled. 4. Have an assistant depress the brake pedal with a slow even strokes until pressure is felt, then hold it. CAUTION: Do not depress brake pedal fully to the end of the master cylinder stroke. This may cause damage to the master cylinder. 5. Starting at the bleeder screw farthest from the master cylinder, using a suitable wrench, open the bleeder valve one full turn. Watch for air bubbles in the fluid, and listen for air escaping from the system. 6. With the brake pedal still depressed, close the bleeder valve. 7. Have the assistant pump the brake pedal several times, then repeat procedure until air no longer is noticed when bleeder is opened. CAUTION: Do not depress brake pedal fully to the end of the master cylinder stroke, this may cause damage to the master cylinder. 8. Repeat previous steps for all bleeders following the wheel bleeding sequence specified in Hydraulic Brake System/Specifications. Ensure all air is removed from the hydraulic system. CAUTION: While bleeding the system, inspect brake fluid supply in the master cylinder often so as not to allow the master cylinder to run dry. 9. Upon completion of hydraulic system bleeding proceed as follows: a. Ensure the master cylinder reservoir is full. Add suitable brake fluid as needed, and securely reinstall the master cylinder cap. b. Lower the vehicle. Ensure brakes operate properly and pedal is firm. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > ABS Warning Lamp Circuit Operation Brake Warning Indicator: Description and Operation ABS Warning Lamp Circuit Operation CIRCUIT OPERATION The ABS warning lamp is an output from the Controller Anti Lock Brake (CAB) and the Anti-lock Brakes System (ABS) relay box. It is used to alert the operator of a problem in the ABS system. The G19 circuit from the CAB and the ABS system relay is used to detect a problem. If a problem is detected, the CAB grounds the G19 circuit and illuminates the lamp in the instrument cluster. Circuit G19 is also an output of the CAB to the ABS system relay contact side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > ABS Warning Lamp Circuit Operation > Page 4167 Brake Warning Indicator: Description and Operation Brake Warning Lamp Circuit Operation CIRCUIT OPERATION The Brake Warning Indicator lamp is used to alert the operator of a problem with the vehicles braking system. The lamp illuminates when the ignition switch is turned to START position to perform a self check. There are two switches used in this system and they are wired in parallel form. A parking brake switch located on the parking brake mechanism will illuminate the lamp if the normally OPEN switch is CLOSED. This switch is case grounded. The other switch used is the brake warning lamp switch. This switch is normally OPEN. When the brake system pressure is below a predetermined level the switch CLOSES and completes a path to ground from the G9 circuit at the cluster, through the switch, to the left headlamp ground. If the vehicle is built for use in Canada the parking brake switch is used for the Daytime Running Lamp Module (DRL). See: Lighting and Horns/Daytime Running Lamp/Daytime Running Lamp Control Unit/Description and Operation Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Page 4168 Brake Warning Indicator: Testing and Inspection - Check the 5 Amp fuse in cavity 11 of the fuse block. - Check the 4 Amp fuse in cavity 12 of the fuse block. - Check the Ignition-Off Draw fuse in the PDC. - Check for a good ground at the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Bore and Piston Dimensions Brake Caliper: Specifications Bore and Piston Dimensions Caliper Piston Outside Diameter 2.125 in Caliper Piston Diameter Solid 1.34 in Vented 1.42 in Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Bore and Piston Dimensions > Page 4174 Brake Caliper: Specifications Torque Specs Brake Caliper to Steering Knuckle Torque Brake Caliper to Steering Knuckle Torque Brake Caliper Bolt 31 Nm Bearing Retainer Bolts 21 ft.lb Brake Hose To Caliper Banjo Bolt 35 ft.lb Brake Line Fitting 12 ft.lb Support Plate To Rear Axle 80 ft.lb Bleed Screws 10 ft.lb Caliper Mounting Bolts 16 ft.lb Caliper Guide Pins 30 ft.lb Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1. Remove caliper as outlined under Brake Pad/Service and Repair. 2. Disconnect Brake Line. 3. Reverse procedure to install, bleed brakes as outlined under Hydraulic System/ Service and Repair/Brake System Bleed. Rear 1. Raise and support vehicle. 2. Remove rear wheel and tire assembly. 3. Remove caliper retaining bolts, then lift caliper away from adapter rails. Hang caliper from wire away from rotor. 4. Remove outer brake pad by prying pad retaining clip over raised area on caliper, then sliding it down and off caliper. 5. Remove inner brake pad by pulling it away from the piston. 6. Retract piston, then reverse procedure to install. Torque caliper retaining bolts to specifications. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4177 Brake Caliper: Service and Repair Disassembly and Assembly Front DISASSEMBLE 1. Remove caliper assembly as described under Brake Pad/Service and Repair. 2. Place a wood block between caliper piston and caliper fingers. With brake hose attached to caliper, carefully depress brake pedal to push piston out of caliper bore. Prop brake pedal to any position below first inch of brake pedal travel to prevent brake fluid loss. 3. If piston are to be removed from both calipers, disconnect brake hose at frame bracket after removing piston, then cap brake line and repeat procedure to remove piston from other caliper. 4. Disconnect brake hose from caliper. 5. Mount caliper in a soft jawed vise. 6. Support caliper, then remove and discard dust boot. 7. Using a small wooden or plastic stick, remove seal from groove in piston bore and discard. CAUTION: Do not use a screwdriver or other metal tool, as this may scratch caliper bore. 8. Remove caliper bushings. ASSEMBLE 1. Mount caliper in a soft jawed vise. 2. Lubricate piston seal with clean brake fluid and install seal in caliper bore groove. Ensure seal is properly seated. 3. Lubricate piston boot with clean brake fluid and position over piston. 4. Install piston and boot assembly, pushing it past piston seal until it bottoms into caliper bore. 5. Using a hammer and dust boot installer tool No. C-4689 with handle tool No. C-4171, or equivalents, drive dust boot into counterbore until properly seated. 6. On models where bushings require replacement, compress flanges of bushings and install on caliper housing. Ensure bushing flanges extend evenly over caliper housing on both sides. Remove Teflon sleeves from guide pin bushings prior to installing bushings into caliper. After bushings are installed into caliper, reinstall Teflon sleeves into bushings. 7. Connect brake hose to brake line at frame bracket. . Install caliper on vehicle as described under Brake Pad/Service and Repair. 9. Bleed brakes as outlined under Hydraulic System/Service and Repair/Brake System Bleed. Rear 1. Remove caliper from rotor as described under Brake Pad/Service and Repair. 2. Place a small piece of wood between piston and caliper fingers, then carefully depress brake pedal to hydraulically push piston out of bore. Prop brake pedal to any position below first inch of brake pedal travel to prevent brake fluid loss. 3. If pistons are to be removed from both calipers, disconnect brake hose at frame bracket after removing piston, then cap brake line and repeat procedure to remove piston from other caliper. 4. Disconnect brake hose from caliper. 5. Mount caliper in a soft jawed vise. 6. Support caliper, then remove and discard dust boot. 7. Using a small wooden or plastic stick, remove seal from groove in piston bore and discard. CAUTION: Do not use a screwdriver or other metal tool, as this may scratch caliper bore. 8. If necessary, remove bushing and sleeve assembly, as follows: a. Using fingers, push inner sleeve until it pops out of bushing, then pull inner sleeve completely out of bushing. b. Using fingers collapse one side of bushing. Pull opposite side of bushing to remove from caliper. 9. Using denatured alcohol or equivalent, thoroughly clean piston and caliper grooves, caliper housing and bushing mounting surfaces. 10. Dip new piston seal in clean brake fluid and install in groove in bore. 11. Coat new piston boot with clean brake fluid leaving a generous amount inside boot. 12. Coat piston with clean brake fluid, then position dust boot over piston. 13. Install piston into bore pushing it past piston seal until it bottoms in bore. 14. Position dust boot in counterbore, then using a hammer and installer tool No. C-4383-7, or equivalent, drive boot into counterbore of caliper. 15. If removed, install guide pin sleeve bushings as follows: a. Fold bushing in half lengthwise at solid middle section. b. Using fingers, insert folded bushing into caliper. Do not use sharp object to perform this step. c. Using wooden dowel, unfold bushing until it is fully seated in caliper. Flanges should be seated evenly on both sides of bushing hole. 16. If removed, install guide pin sleeve as follows: a. Hold end of bushing, then push sleeve through bushing until end of bushing is fully seated into seal groove of sleeve. b. Holding sleeve in place, install other end of bushing into seal groove. c. Ensure bushing is in seal groove on both sides. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4178 17. Install brake fluid line, then install caliper as outlined under Brake Pad/Service and Repair. 18. Bleed brakes as outlined under Hydraulic System/Service and Repair/Brake System Bleed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest: > 05-10-97 > Dec > 97 > Front Brakes - Squeal or Creep/Groan Brake Pad: Customer Interest Front Brakes - Squeal or Creep/Groan NO: 05-10-97 GROUP: Brakes DATE: Dec. 19, 1997 SUBJECT: Front Brake Squeal And/Or Creep/Groan MODELS: 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES WITH 14" DISC/DRUM (SALES CODE BRA AND BRJ). SYMPTOM/CONDITION: Front brake squeal moderate brake pedal application, or creep/groan sound during zero speed creeping brake apply. DIAGNOSIS: 1. Drive the vehicle at 10 to 20 MPH, with moderate pressure apply the brakes. If a squeal sound is heard perform the Repair Procedure. 2. With the brake pedal applied, place the transmission in "drive" and slowly release the brakes until the vehicle just begins to creep. If a loud grinding, crunching, or groaning noise is heard from the front brakes, perform the Repair Procedure. PARTS REQUIRED: 1 05011069AA Pad Set, Front Disc Brake REPAIR PROCEDURE: This bulletin involves the replacement of the front brake pads. 1. Remove and replace the front brake pads following the repair procedure provided in the appropriate Neon Service Manual, Group 5. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-70-22-90 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-10-97 > Dec > 97 > Front Brakes - Squeal or Creep/Groan Brake Pad: All Technical Service Bulletins Front Brakes - Squeal or Creep/Groan NO: 05-10-97 GROUP: Brakes DATE: Dec. 19, 1997 SUBJECT: Front Brake Squeal And/Or Creep/Groan MODELS: 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES WITH 14" DISC/DRUM (SALES CODE BRA AND BRJ). SYMPTOM/CONDITION: Front brake squeal moderate brake pedal application, or creep/groan sound during zero speed creeping brake apply. DIAGNOSIS: 1. Drive the vehicle at 10 to 20 MPH, with moderate pressure apply the brakes. If a squeal sound is heard perform the Repair Procedure. 2. With the brake pedal applied, place the transmission in "drive" and slowly release the brakes until the vehicle just begins to creep. If a loud grinding, crunching, or groaning noise is heard from the front brakes, perform the Repair Procedure. PARTS REQUIRED: 1 05011069AA Pad Set, Front Disc Brake REPAIR PROCEDURE: This bulletin involves the replacement of the front brake pads. 1. Remove and replace the front brake pads following the repair procedure provided in the appropriate Neon Service Manual, Group 5. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-70-22-90 0.5 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 02-09-99 > Jul > 99 > Steering/Suspension Smooth Road Vibration Control Arm Bushing: All Technical Service Bulletins Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 02-09-99 > Jul > 99 > Steering/Suspension Smooth Road Vibration > Page 4197 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 02-09-99 > Jul > 99 > Steering/Suspension Smooth Road Vibration > Page 4198 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 02-09-99 > Jul > 99 > Steering/Suspension Smooth Road Vibration > Page 4204 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 02-09-99 > Jul > 99 > Steering/Suspension Smooth Road Vibration > Page 4205 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front REMOVAL 1. Remove half of brake fluid from reservoir. 2. Raise and support front of vehicle. 3. Remove wheel and tire assembly. 4. Remove caliper guide pin bolts, then wedge caliper away from rotor using a screwdriver to break gasket adhesive seals. 5. Remove caliper by slowly sliding assembly out and away from rotor. NOTE: Suspend caliper with wire to avoid damaging brake hose. 6. Remove outboard pad, then the inboard pad by sliding off of adapter. INSTALLATION 1. Lubricate adapter ways with suitable grease. 2. Install inboard pad, then the outboard pad onto adapter. 3. Lower caliper over rotor and pad assemblies, then install guide pins. Tighten pins to specifications. 4. Install tire and wheel assembly, then lower vehicle. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 4208 Brake Pad: Service and Repair Rear 1. Raise and support vehicle. 2. Remove rear wheel and tire assembly. 3. Remove caliper retaining bolts, then lift caliper away from adapter rails. Hang caliper from wire away from rotor. 4. Remove outer brake pad by prying pad retaining clip over raised area on caliper, then sliding it down and off caliper. 5. Remove inner brake pad by pulling it away from the piston. 6. Retract piston, then reverse procedure to install. Torque caliper retaining bolts to specifications. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Front Brake Rotor/Disc: Specifications Nominal Thickness 0.782-0.792 in Minimum Refinish Thickness 0.724 in Thickness Variation (Parallelism) 0.0005 in Lateral Runout (T.I.R.) 0.005 in Finish, Micro-Inch 15-80 micro-in Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Front > Page 4213 Brake Rotor/Disc: Specifications Minimum Allowable Thickness Refer to stamping on rotor's un-machined surface. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor/Disc: Service and Repair Front Remove caliper as outlined under Brake Caliper/Service and Repair, then remove rotor. Use a suitable soft face hammer if necessary to tap rotor free of hub. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 4216 Brake Rotor/Disc: Service and Repair Rear 1. Remove caliper as outlined under Brake Caliper/Service and Repair. 2. Remove parking brake adjustment hole plug from hub of brake disc. 3. Using a suitable tool, turn parking brake adjusting nut until brake disc can be removed. 4. Reverse procedure to install. Adjust parking brake as outlined under Parking Brake System/Adjustments. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Customer Interest for Backing Plate: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Customer Interest for Backing Plate: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 4226 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Backing Plate: > 05-01-98 > Jan > 98 > Rear Brakes Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Backing Plate: > 05-01-98 > Jan > 98 > Rear Brakes Howl During Low Speed Stop > Page 4232 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Page 4233 Backing Plate: Testing and Inspection Inspect backing plate shoe contact surface for grooves that may restrict shoe movement and cannot be removed by lightly sanding with emery cloth or other suitable abrasive. If backing plate exhibits above condition, it should be replaced. Also inspect for signs of cracks, warpage and excessive rust, indicating need for replacement. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Adjuster > Component Information > Testing and Inspection Brake Adjuster: Testing and Inspection ADJUSTER MECHANISM Inspect all components for rust, corrosion, bends and fatigue. Replace as necessary. On adjuster mechanism equipped with adjuster cable, inspect cable for kinks, fraying or elongation of eyelet and replace as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Brake Drum Inside Diameter Maximum refinishing diameter is stamped on drum's outer face. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 4240 Brake Drum: Testing and Inspection Any time the brake drums are removed for brake service, the braking surface diameter should be inspected with a suitable brake drum micrometer at several points to determine if they are within the safe oversize limit stamped on the brake drum outer surface. If the braking surface diameter exceeds specifications, the drum must be replaced. If the braking surface diameter is within specifications, drums should be cleaned and inspected for cracks, scores, deep grooves, taper, out of round and heat spotting. If drums are cracked or heat spotted, they must be replaced. Scoring and grooves in the braking surface can only be removed by machining with special equipment, as long as the braking surface is within specifications. Any brake drum showing taper or sufficiently out of round to cause vehicle vibration or noise while braking should also be machined, removing only enough stock to true up the drum. After a brake drum is machined, wipe the braking surface diameter with a denatured alcohol soaked cloth. If one brake drum is machined, the other should also be machined to the same diameter to maintain equal braking forces. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Customer Interest for Brake Shoe: > 050396 > Feb > 96 > Rear Brakes - Howl at The End of a Stop Brake Shoe: Customer Interest Rear Brakes - Howl at The End of a Stop N0. 05-03-96 GROUP: Brakes DATE: Feb. 23, 1996 SUBJECT: Rear Brake Howl MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: A howl noise coming from the rear brakes at the end of a stop, usually from 5 - 0 MPH. This noise can range from a low volume, to a very loud sound that may appear to come from the front brakes. NOTE: THIS REPAIR HAS NO EFFECT ON THE CYCLIC REAR BRAKE NOISE WHICH OCCURS AT LOW SPEEDS DURING MEDIUM TO LIGHT BRAKE APPLICATIONS. PARTS REQUIRED: 1 4762537 Rear Shoe and Lining Kit REPAIR PROCEDURE: This bulletin involves the replacement of the rear brake shoes with a new lining material. 1. Replace the rear brake shoes, following the procedure given in the 1996 Neon Service Manual (P/N 81-270-6025) on page 5-35. CAUTION: THIS REPAIR SHOULD BE PERFORMED WITHOUT TURNING THE BRAKE DRUMS (UNLESS DRUMS SHOW A MECHANICAL REASON). NEW BRAKE SHOE LINING ARE THE MOST EFFECTIVE REPAIR FOR THIS COMPLAINT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-70-06-98 0.8 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Shoe: > 050396 > Feb > 96 > Rear Brakes - Howl at The End of a Stop Brake Shoe: All Technical Service Bulletins Rear Brakes - Howl at The End of a Stop N0. 05-03-96 GROUP: Brakes DATE: Feb. 23, 1996 SUBJECT: Rear Brake Howl MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: A howl noise coming from the rear brakes at the end of a stop, usually from 5 - 0 MPH. This noise can range from a low volume, to a very loud sound that may appear to come from the front brakes. NOTE: THIS REPAIR HAS NO EFFECT ON THE CYCLIC REAR BRAKE NOISE WHICH OCCURS AT LOW SPEEDS DURING MEDIUM TO LIGHT BRAKE APPLICATIONS. PARTS REQUIRED: 1 4762537 Rear Shoe and Lining Kit REPAIR PROCEDURE: This bulletin involves the replacement of the rear brake shoes with a new lining material. 1. Replace the rear brake shoes, following the procedure given in the 1996 Neon Service Manual (P/N 81-270-6025) on page 5-35. CAUTION: THIS REPAIR SHOULD BE PERFORMED WITHOUT TURNING THE BRAKE DRUMS (UNLESS DRUMS SHOW A MECHANICAL REASON). NEW BRAKE SHOE LINING ARE THE MOST EFFECTIVE REPAIR FOR THIS COMPLAINT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-70-06-98 0.8 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation Brake Shoe: Service and Repair Brake Shoe Removal and Installation Removal 1. Raise and support rear of vehicle. 2. Remove tire and wheel assembly, then remove brake drum. If brake lining is dragging on brake drum, back off brake adjustment by rotating adjustment screw. Fig. 1 Kelsey-Hayes Leading Trailing Drum Brake Assembly. Type 2 3. Using suitable pliers, remove adjuster lever spring. 4. Remove adjuster lever. 5. Turn automatic adjuster screw out to expand shoes past wheel cylinder boot. 6. Disconnect parking brake cable from parking brake lever. 7. On Kelsey Hayes brake assemblies, using suitable tool, remove hold-down springs. Pull brake shoe assembly down and away from anchor plate, then remove brake shoe springs and adjusting screw assembly. Fig 3 Varga Leading Trailing Drum Brake Assembly 8. On Varga brake assemblies, remove upper shoe to shoe return spring on leading shoe, leading shoe hold-down spring, shoe to shoe spring at Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4256 anchor plate, then the shoe and adjuster assembly. 9. On all models, remove hold-down spring and lower shoe to anchor plate spring for trailing shoe. 10. On Kelsey Hayes brake assemblies, remove C-clip retaining parking brake lever to trailing brake shoe webbing. 11. On Varga brake assemblies, remove parking brake lever from trailing shoe by prying retainer tangs apart. 12. On all models, clean dirt from brake drum, anchor plate and all other components. Do not use compressed air or dry brush to clean brake parts. Many brake parts contain asbestos fibers, which, if inhaled, can cause serious injury. To clean brake parts, use a water soaked rag or a suitable vacuum cleaner to minimize airborne dust. Installation KELSEY-HAYES BRAKE ASSEMBLY 1. Lightly lubricate anchor plate shoe contact surfaces with suitable brake lube. 2. Remove brake drum hub grease seal and bearings, then clean and repack bearings and reinstall. Install new grease seal. 3. Assemble automatic adjuster screw assembly, return spring and shoe-to-shoe spring to brake shoe assembly. 4. Position lining assembly near anchor plate, then assemble parking brake lever to trailing shoe webbing. Secure with C-clip. 5. Install lining assembly onto anchor plate. When positioned, back off adjuster nut to seat brake shoe ends in wheel cylinder. 6. Install hold-down springs. 7. Position adjuster lever, then using suitable pliers, install adjuster lever spring. 8. Install brake drum and bearings. Refer to individual car chapter for wheel bearing adjustment procedure. 9. Adjust brakes. 10. Install tire and wheel assembly. 11. If any hydraulic connections have been opened, bleed brake system. 12. Inspect master cylinder level, and replenish as necessary. 13. Inspect brake pedal for proper feel and return. 14. Lower vehicle and road test. Do not severely apply brakes immediately after installation of new brake linings or permanent damage may occur to linings and/or brake drums may become scored. Brakes must be used moderately during first several hundred miles of operation to ensure proper burnishing. VARGA BRAKE ASSEMBLY 1. Assemble park brake lever and wave washer to trailing shoe, then install retainer and close ends. 2. Install park brake cable in lever of trailing shoe, then attach trailing shoe and leading shoe lower springs to shoes and anchor plate. 3. Position shoes on support plate and install hold-down springs. 4. Install automatic adjusters, ends must be above extruded pins in web of shoe. Lefthand side adjuster has lefthand threads. Righthand side adjuster has righthand threads. Do not interchange them. 5. Install upper shoe to shoe spring, then rotate adjuster to remove freeplay from adjuster assembly. 6. Install adjuster lever on leading pivot pin and attach short end of adjuster spring in hole of lever and long end in leading shoe hole. 7. Connect park brake cable and adjust shoes so that they do not interfere with drum installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 4257 Brake Shoe: Service and Repair Cleaning and Inspection Inspect brake linings for excessive wear, damage, oil, grease or brake fluid contamination. If any of the above conditions exist, brake linings should be replaced as an axle set to maintain equal braking forces. Examine brake shoe webbing, hold-down and return springs for signs of overheating indicated by a slight blue color. Any component which exhibits overheating signs should be replaced. Overheated springs lose their pull and could cause brake linings to wear out prematurely. Inspect all springs for sags, bends and external damage and replace as necessary. Inspect hold-down retainers and pins for bends, rust and corrosion. If any of the above is found, replace as required. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cylinder: > 050596 > May > 96 > Rear Brakes Cyclic Chirping Noise Wheel Cylinder: Customer Interest Rear Brakes - Cyclic Chirping Noise NO: 05-05-96 GROUP: Brakes DATE: May 5, 1996 SUBJECT: Rear Brake Cyclic Chirp NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-04-96 DATED MARCH 8, 1996 AND TECHNICAL SERVICE BULLETIN 05-06-95 DATED MAY 19, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE 1996 SEBRING CONVERTIBLE HAS BEEN ADDED AND THE "PROTECT -A- CUP", LUBE IS NOW AVAILABLE THRU MOPAR PARTS. ALL CHANGES ARE MARKED WITH **ASTERISKS** MODELS: 1995 - 1996 (PL) Neon 1996 (JX) Sebring Convertible** SYMPTOM/CONDITION: A cyclic chirp noise from the rear of the vehicle during medium to light brake application, at low speeds (20 mph or less) on vehicles equipped with rear drum brakes. The noise can be related to the speed at which the tire turns (one squeak/squawk per revolution of the tire). As the vehicle slows, during the brake application, the noise will occur at a slower rate. **NOTE: THIS REPAIR HAS NO EFFECT ON THE REAR BRAKE HOWL NOISE THAT MAY OCCUR ON NEONS, AT THE END OF THE STOP. THE REAR BRAKE HOWL NOISE IS COVERED IN A SEPARATE TECHNICAL SERVICE BULLETIN.** PARTS REQUIRED: 1 4883068 "Protect -A- Cup" (Lube Cap) REPAIR PROCEDURE: This bulletin involves the installation of 4 drops of the "Protect -A- Cup" lubricant into each rear wheel cylinder. 1. Raise car on suitable hoist and remove rear wheels. 2. Remove rear brake drum retaining clips (1 per side) and remove rear brake drums. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cylinder: > 050596 > May > 96 > Rear Brakes Cyclic Chirping Noise > Page 4266 3. Peel back the top edge of the wheel cylinder boot and put four drops of the "Protect - A - Cup" fluid into the wheel cylinder. This fluid acts as a lubricant between the wheel cylinder the piston and the wheel cylinder boot (Figure 1). 4. Install the wheel cylinder boot onto the wheel cylinder casting. Make sure that the boot seats properly on the casting lip all the way around the wheel cylinder. 5. Repeat the process for the other three boots (two per brake). CAUTION: THE "PROTECT -A- CUP" ASSEMBLY FLUID USED TO ADDRESS THE CYCLIC CHIRP NOISE SHOULD NOT BE USED FOR ANY PURPOSE IN THE VEHICLE1S BRAKE SYSTEM OTHER THAN AS DESCRIBED IN THIS TSB. 6. Wipe any spilled fluid from the outside of the wheel cylinder as well as any other brake parts including the linings. 7. Install the brake drums, retaining clips and rear wheels. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-90-50-93 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cylinder: > 050596 > May > 96 > Rear Brakes - Cyclic Chirping Noise Wheel Cylinder: All Technical Service Bulletins Rear Brakes - Cyclic Chirping Noise NO: 05-05-96 GROUP: Brakes DATE: May 5, 1996 SUBJECT: Rear Brake Cyclic Chirp NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-04-96 DATED MARCH 8, 1996 AND TECHNICAL SERVICE BULLETIN 05-06-95 DATED MAY 19, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE 1996 SEBRING CONVERTIBLE HAS BEEN ADDED AND THE "PROTECT -A- CUP", LUBE IS NOW AVAILABLE THRU MOPAR PARTS. ALL CHANGES ARE MARKED WITH **ASTERISKS** MODELS: 1995 - 1996 (PL) Neon 1996 (JX) Sebring Convertible** SYMPTOM/CONDITION: A cyclic chirp noise from the rear of the vehicle during medium to light brake application, at low speeds (20 mph or less) on vehicles equipped with rear drum brakes. The noise can be related to the speed at which the tire turns (one squeak/squawk per revolution of the tire). As the vehicle slows, during the brake application, the noise will occur at a slower rate. **NOTE: THIS REPAIR HAS NO EFFECT ON THE REAR BRAKE HOWL NOISE THAT MAY OCCUR ON NEONS, AT THE END OF THE STOP. THE REAR BRAKE HOWL NOISE IS COVERED IN A SEPARATE TECHNICAL SERVICE BULLETIN.** PARTS REQUIRED: 1 4883068 "Protect -A- Cup" (Lube Cap) REPAIR PROCEDURE: This bulletin involves the installation of 4 drops of the "Protect -A- Cup" lubricant into each rear wheel cylinder. 1. Raise car on suitable hoist and remove rear wheels. 2. Remove rear brake drum retaining clips (1 per side) and remove rear brake drums. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cylinder: > 050596 > May > 96 > Rear Brakes - Cyclic Chirping Noise > Page 4272 3. Peel back the top edge of the wheel cylinder boot and put four drops of the "Protect - A - Cup" fluid into the wheel cylinder. This fluid acts as a lubricant between the wheel cylinder the piston and the wheel cylinder boot (Figure 1). 4. Install the wheel cylinder boot onto the wheel cylinder casting. Make sure that the boot seats properly on the casting lip all the way around the wheel cylinder. 5. Repeat the process for the other three boots (two per brake). CAUTION: THE "PROTECT -A- CUP" ASSEMBLY FLUID USED TO ADDRESS THE CYCLIC CHIRP NOISE SHOULD NOT BE USED FOR ANY PURPOSE IN THE VEHICLE1S BRAKE SYSTEM OTHER THAN AS DESCRIBED IN THIS TSB. 6. Wipe any spilled fluid from the outside of the wheel cylinder as well as any other brake parts including the linings. 7. Install the brake drums, retaining clips and rear wheels. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-90-50-93 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 4273 Wheel Cylinder: Specifications Bearing Retainer Bolts 160 ft.lb Brake Line Fittings 12 ft.lb Support Plate To Rear Axle 85 ft.lb Wheel Cylinder Bleed Screws 6 ft.lb Wheel Cylinder To Backing Plate 6 ft.lb Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation REMOVAL 1. Remove wheel, drum and brake shoes. 2. Loosen brake line fitting at wheel cylinder. Do not pull metal line away from cylinder. 3. Remove screws holding cylinder to backing plate. 4. Separate wheel cylinder from brake line and backing plate by pulling the cylinder outward and away from backing plate. INSTALLATION 1. Wipe end of hydraulic line to remove any foreign matter. 2. Position wheel cylinder to backing plate. Install brake line to cylinder and start connecting fitting. 3. Secure wheel cylinder to backing plate, then complete tightening of brake line fitting. 4. Install brake shoes, drum and wheel. 5. Bleed system as outlined previously, and adjust brakes. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4276 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul Note position of all parts as they are removed for proper installation. DISASSEMBLE Fig 28 Disassembled View Of Typical Wheel Cylinder 1. Remove boots, pistons, cups and spring from wheel cylinder. 2. Wipe cylinder walls with denatured alcohol or clean brake fluid. 3. Examine cylinder bore. A scored bore may be honed providing the bore diameter is not increased more than 0.005 inch. Replace as necessary. 4. Check pistons for wear or damage. Replace as necessary. ASSEMBLE 1. Before assembling, wash hands with soap and water so as not to contaminate rubber parts. 2. Use all parts contained in repair kit. Lubricate cylinder wall and rubber cups with brake fluid. 3. Properly install spring, cups, pistons and boots in housing. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Wheel Bleed Sequence LR,RF,RR,LF Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding Brake Bleeding: Service and Repair About Brake System Bleeding BASE BRAKE SYSTEM BLEEDING Bleeding the hydraulic brake system is necessary if air has entered the system. A few causes for this condition are low fluid level, a hydraulic fluid leak, a hydraulic line is opened, or replacement of a hydraulic system component. Symptoms can be noted by an improper or loss of brake operation, and/or a low or spongy brake pedal. Flushing the hydraulic brake system is necessary if contaminants are found in the hydraulic system. A few causes for hydraulic system contamination are moisture, age of hydraulic system parts and fluid, or improper fluid used in the system. Symptoms can be noted by an improper or loss of brake operation, swollen and deteriorated cups and other rubber parts, and/or a discoloration of the brake fluid. The hydraulic fluid is bled or flushed from the system through bleeder valves located on the calipers, wheel cylinders, and some master cylinders. When bleeding the hydraulic brake system, use only specified brake fluid, and never reuse old brake fluid removed from the system. PRESSURE BLEEDING Pressure bleeding is recommended for all hydraulic brake systems. It is the fastest method because the master cylinder is automatically fed brake fluid from the pressure bleeder reservoir, and no pedal pumping is needed so only one person is required to perform the procedure. However, if pressure bleeding equipment is not available, the hydraulic system may be bled as described under "Manual Bleed." When pressure bleeding, to prevent air from getting into the hydraulic system, do not shake the pressure tank. Set the tank in the required location, bring the air hose to the tank, and do not move it during the bleeding operation. The tank should be kept at least one-third full. The bleeder valve should be opened at least one full turn, and intermittently closed at about four-second intervals. This gives a whirling action to fluid in the hydraulic system, and helps expel the air. Refer to Hydraulic Brake System/Specifications for proper wheel bleeding sequence. PRECAUTIONS Normal pressure from the pressure bleeder should not be greater than about 35 PSI. On vehicles equipped with plastic reservoirs, do not exceed 25 PSI bleeding pressure. On models with hold-off valves contained in the combination valve, the valve stem on the outside of the combination valve must be held in position during bleeding using valve holding tool No. C-4121, or equivalent. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 4283 Brake Bleeding: Service and Repair Base Brake System Bleeding On models with power brakes, bleed the hydraulic system without the engine running. Reduce vacuum in the power unit to zero by pumping the brake pedal several times with the engine Off. 1. Ensure master cylinder reservoir is full. 2. Raise and support vehicle. 3. Position a drain pan under the wheel being bled. 4. Have an assistant depress the brake pedal with a slow even strokes until pressure is felt, then hold it. CAUTION: Do not depress brake pedal fully to the end of the master cylinder stroke. This may cause damage to the master cylinder. 5. Starting at the bleeder screw farthest from the master cylinder, using a suitable wrench, open the bleeder valve one full turn. Watch for air bubbles in the fluid, and listen for air escaping from the system. 6. With the brake pedal still depressed, close the bleeder valve. 7. Have the assistant pump the brake pedal several times, then repeat procedure until air no longer is noticed when bleeder is opened. CAUTION: Do not depress brake pedal fully to the end of the master cylinder stroke, this may cause damage to the master cylinder. 8. Repeat previous steps for all bleeders following the wheel bleeding sequence specified in Hydraulic Brake System/Specifications. Ensure all air is removed from the hydraulic system. CAUTION: While bleeding the system, inspect brake fluid supply in the master cylinder often so as not to allow the master cylinder to run dry. 9. Upon completion of hydraulic system bleeding proceed as follows: a. Ensure the master cylinder reservoir is full. Add suitable brake fluid as needed, and securely reinstall the master cylinder cap. b. Lower the vehicle. Ensure brakes operate properly and pedal is firm. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Bore and Piston Dimensions Brake Caliper: Specifications Bore and Piston Dimensions Caliper Piston Outside Diameter 2.125 in Caliper Piston Diameter Solid 1.34 in Vented 1.42 in Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Bore and Piston Dimensions > Page 4288 Brake Caliper: Specifications Torque Specs Brake Caliper to Steering Knuckle Torque Brake Caliper to Steering Knuckle Torque Brake Caliper Bolt 31 Nm Bearing Retainer Bolts 21 ft.lb Brake Hose To Caliper Banjo Bolt 35 ft.lb Brake Line Fitting 12 ft.lb Support Plate To Rear Axle 80 ft.lb Bleed Screws 10 ft.lb Caliper Mounting Bolts 16 ft.lb Caliper Guide Pins 30 ft.lb Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 1. Remove caliper as outlined under Brake Pad/Service and Repair. 2. Disconnect Brake Line. 3. Reverse procedure to install, bleed brakes as outlined under Hydraulic System/ Service and Repair/Brake System Bleed. Rear 1. Raise and support vehicle. 2. Remove rear wheel and tire assembly. 3. Remove caliper retaining bolts, then lift caliper away from adapter rails. Hang caliper from wire away from rotor. 4. Remove outer brake pad by prying pad retaining clip over raised area on caliper, then sliding it down and off caliper. 5. Remove inner brake pad by pulling it away from the piston. 6. Retract piston, then reverse procedure to install. Torque caliper retaining bolts to specifications. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4291 Brake Caliper: Service and Repair Disassembly and Assembly Front DISASSEMBLE 1. Remove caliper assembly as described under Brake Pad/Service and Repair. 2. Place a wood block between caliper piston and caliper fingers. With brake hose attached to caliper, carefully depress brake pedal to push piston out of caliper bore. Prop brake pedal to any position below first inch of brake pedal travel to prevent brake fluid loss. 3. If piston are to be removed from both calipers, disconnect brake hose at frame bracket after removing piston, then cap brake line and repeat procedure to remove piston from other caliper. 4. Disconnect brake hose from caliper. 5. Mount caliper in a soft jawed vise. 6. Support caliper, then remove and discard dust boot. 7. Using a small wooden or plastic stick, remove seal from groove in piston bore and discard. CAUTION: Do not use a screwdriver or other metal tool, as this may scratch caliper bore. 8. Remove caliper bushings. ASSEMBLE 1. Mount caliper in a soft jawed vise. 2. Lubricate piston seal with clean brake fluid and install seal in caliper bore groove. Ensure seal is properly seated. 3. Lubricate piston boot with clean brake fluid and position over piston. 4. Install piston and boot assembly, pushing it past piston seal until it bottoms into caliper bore. 5. Using a hammer and dust boot installer tool No. C-4689 with handle tool No. C-4171, or equivalents, drive dust boot into counterbore until properly seated. 6. On models where bushings require replacement, compress flanges of bushings and install on caliper housing. Ensure bushing flanges extend evenly over caliper housing on both sides. Remove Teflon sleeves from guide pin bushings prior to installing bushings into caliper. After bushings are installed into caliper, reinstall Teflon sleeves into bushings. 7. Connect brake hose to brake line at frame bracket. . Install caliper on vehicle as described under Brake Pad/Service and Repair. 9. Bleed brakes as outlined under Hydraulic System/Service and Repair/Brake System Bleed. Rear 1. Remove caliper from rotor as described under Brake Pad/Service and Repair. 2. Place a small piece of wood between piston and caliper fingers, then carefully depress brake pedal to hydraulically push piston out of bore. Prop brake pedal to any position below first inch of brake pedal travel to prevent brake fluid loss. 3. If pistons are to be removed from both calipers, disconnect brake hose at frame bracket after removing piston, then cap brake line and repeat procedure to remove piston from other caliper. 4. Disconnect brake hose from caliper. 5. Mount caliper in a soft jawed vise. 6. Support caliper, then remove and discard dust boot. 7. Using a small wooden or plastic stick, remove seal from groove in piston bore and discard. CAUTION: Do not use a screwdriver or other metal tool, as this may scratch caliper bore. 8. If necessary, remove bushing and sleeve assembly, as follows: a. Using fingers, push inner sleeve until it pops out of bushing, then pull inner sleeve completely out of bushing. b. Using fingers collapse one side of bushing. Pull opposite side of bushing to remove from caliper. 9. Using denatured alcohol or equivalent, thoroughly clean piston and caliper grooves, caliper housing and bushing mounting surfaces. 10. Dip new piston seal in clean brake fluid and install in groove in bore. 11. Coat new piston boot with clean brake fluid leaving a generous amount inside boot. 12. Coat piston with clean brake fluid, then position dust boot over piston. 13. Install piston into bore pushing it past piston seal until it bottoms in bore. 14. Position dust boot in counterbore, then using a hammer and installer tool No. C-4383-7, or equivalent, drive boot into counterbore of caliper. 15. If removed, install guide pin sleeve bushings as follows: a. Fold bushing in half lengthwise at solid middle section. b. Using fingers, insert folded bushing into caliper. Do not use sharp object to perform this step. c. Using wooden dowel, unfold bushing until it is fully seated in caliper. Flanges should be seated evenly on both sides of bushing hole. 16. If removed, install guide pin sleeve as follows: a. Hold end of bushing, then push sleeve through bushing until end of bushing is fully seated into seal groove of sleeve. b. Holding sleeve in place, install other end of bushing into seal groove. c. Ensure bushing is in seal groove on both sides. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 4292 17. Install brake fluid line, then install caliper as outlined under Brake Pad/Service and Repair. 18. Bleed brakes as outlined under Hydraulic System/Service and Repair/Brake System Bleed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Use new brake fluid only, to top off the master cylinder or refill system. Never use reclaimed fluid, unmarked or unspecified fluid, fluid not meeting SAE/DOT standards, fluid marked 70R1, or fluid from a container that has been left open. Brake Fluid Type DOT 3 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service Precautions Brake Hose/Line: Service Precautions WARNING: NEVER use copper tubing as a replacement for steel tubing. Copper tubing is subject to fatigue cracking and corrosion which could result in brake system failure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service Precautions > Page 4299 Brake Hose/Line: Testing and Inspection Steel tubing is used to transfer hydraulic pressure to the brakes. All fittings, tubing and hose should be inspected for rust, damage or defective flared seats. The tubing is equipped with a double flare/inverted seat or ISO flare to ensure more positive seating in the fitting. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service Precautions > Page 4300 Brake Hose/Line: Service and Repair WARNING: Never use copper tubing as a replacement for steel tubing. Copper tubing is subject to fatigue cracking and corrosion which could result in brake system failure. Steel tubing is used to transfer hydraulic pressure to the brakes. All fittings, tubing and hose should be inspected for rust, damage or defective flared seats. The tubing is equipped with a double flare/inverted seat or ISO flare to ensure more positive seating in the fitting. DOUBLE FLARE/INVERTED SEAT Cutting And Flaring Of Brake Fluid Tubing 1. Using the tool shown, or equivalent, cut off the damaged seat or damaged tubing. 2. Ream out any burrs or rough edges showing on inside edges of tubing. This will make the ends of the tubing square and ensure better seating on the flared end. Before flaring tubing, place a compression nut on tubing. 3. Open handles of flaring tool and rotate jaws of tool until mating jaws of tubing size are centered in the area between vertical posts. 4. Slowly close handles with tubing inserted in jaws but do not apply heavy pressure to handle as this will lock tubing in place. 5. Place gauge on edge over end of tubing and push tubing through jaws until end of tubing contacts recessed notch of gauge matching size of tubing. 6. Squeeze handles of flaring tool and lock tubing in place. 7. Place proper size plug of gauge down in end of tubing. Swing compression disc over gauge and center tapered flaring screw in recess in disc. 8. Lubricate taper of flaring or screw and screw in until plug gauge has seated in jaws of flaring tool. This action has started to invert the extended end of tubing. 9. Remove gauge and apply lubricant to tapered end of flaring screw and continue to screw down until tool is firmly seated in tubing. 10. Remove tubing from flaring tool and inspect the seat. If seat is cracked, cut off cracked end and repeat flaring operation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Proportioning Valve - Pressure Adapter Tool Revision Brake Proportioning/Combination Valve: Technical Service Bulletins Proportioning Valve - Pressure Adapter Tool Revision NUMBER: 05-03-00 GROUP: Brakes DATE: April 14, 2000 SUBJECT: Proportioning Valve Brake Pressure Adapter Tool Revision MODELS: 1995-1999 (PL) Neon DISCUSSION: Figure 1 Diagnosing and testing the brake proportioning valves following the procedure in the appropriate Neon Service Manual calls for the use of the Brake Pressure Adapter Set 6805 and Brake Gauge Set C-4007-A. Alternate adapters from prior tool shipments should now be used on the Neon in place of the adapters provided in the Brake Pressure Adapter Set 6805. When the Neon Service Manual calls for Adapter 6805-3, use Adapter 8187-2 (Figure 1) which was shipped with the 1998 Concorde/Intrepid special tools in kit 8180CC or stored on panel 78. When the Neon Service Manual calls for Adapter 6805-4, use Adapter 6833-1 (Figure 1) which was shipped in the 1996 Minivan special tool kit and stored on panel 70. If you are unable to locate these adapters (6833-1 & 8187-2), they are available separately through Miller Special Tools (1-800-801-5420). POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > With Antilock Brakes Brake Proportioning/Combination Valve: Specifications With Antilock Brakes Valve Tag Color [01] ............................................................................................................................ ......................................................................... Gold Split Point psi/Slope .......................................... ......................................................................................................................................................... 400/.34 Inlet Pressure From Master Cylinder psi ................................................................................ ........................................................................................ 1000 Outlet Pressure To Rear Brakes psi .. .............................................................................................................................................................. .......... 550-650 Footnotes: [1] Color tag located under boot of valve stem. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > With Antilock Brakes > Page 4307 Brake Proportioning/Combination Valve: Specifications Without Antilock Brakes With 13 Inch Disc/Drum System Valve Tag Color [01] ............................................................................................................................ ......................................................................... Gold Split Point psi/Slope .......................................... ......................................................................................................................................................... 400/.34 Inlet Pressure From Master Cylinder psi ................................................................................ ........................................................................................ 1000 Outlet Pressure To Rear Brakes psi .. .............................................................................................................................................................. .......... 550-650 Footnotes: [1] Color tag located under boot of valve stem. With 14 Inch Disc/Disc System Valve Tag Color [01] ............................................................................................................................ ......................................................................... Gold Split Point psi/Slope .......................................... ......................................................................................................................................................... 400/.34 Inlet Pressure From Master Cylinder psi ................................................................................ ........................................................................................ 1000 Outlet Pressure To Rear Brakes psi .. .............................................................................................................................................................. .......... 550-650 Footnotes: [1] Color tag located under boot of valve stem. With 14 Inch Disc/Drum System Valve Tag Color [01] ............................................................................................................................ ........................................................................ Black Split Point psi/Slope .......................................... ......................................................................................................................................................... 400/.43 Inlet Pressure From Master Cylinder psi ................................................................................ ........................................................................................ 1000 Outlet Pressure To Rear Brakes psi .. .............................................................................................................................................................. .......... 600-700 Footnotes: [1] Color tag located under boot of valve stem. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 4308 Brake Proportioning/Combination Valve: Description and Operation This system uses proportioning valves to balance front to rear braking by controlling, at a given ratio, the increase in rear brake system hydraulic pressure above a preset level. Under light pedal application, the proportioning valves allow full hydraulic pressure to be applied to the rear brakes. Fig 35 Type 3 Proportioning Valve Identification There are two proportioning valve assemblies used in each vehicle. Due to differences in thread size, each valve has a different part number. During any service procedures, identify valve assemblies by part number or color code. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 4309 Brake Proportioning/Combination Valve: Testing and Inspection Fig 36 Type 3 Proportioning Valve Test Fittings The in-line proportioning valves used in this system require special pressure fittings set No. 6805, or equivalent, to test for proper valve function. The fittings are installed before and after the proportioning valve being tested to verify valve is maintaining the required hydraulic pressure to the rear wheel brake which it controls. The pressure gauges used for testing the in-line proportioning valves on both non-ABS and ABS systems is Pressure Gauge Set No. C-4007-A, or equivalent. If a condition of premature wheel skid occurs on a vehicle, the proportioning valve should always be tested prior to being replaced as there are conditions other than a faulty proportioning valve that can cause premature wheel skid, such as worn, contaminated or improper brake linings. LESS ANTI-LOCK BRAKE SYSTEM Fig 37 Type 3 Proportioning Valve Location. Neon Less ABS Fig 38 Type 3 Proportioning Valve Location 1. Road test vehicle to determine which rear wheel exhibits premature wheel skid. Refer to the images to determine which proportioning valve needs Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > Page 4310 to be tested. 2. Remove hydraulic brake line from proportioning valve to be tested, then remove valve from master cylinder outlet port. 3. Install Pressure Test Fitting Tool No. 6805-1 or 6805-2, or equivalent, depending on the thread size, into outlet port of master cylinder. 4. Install proportioning valve into pressure test fitting. 5. Install Pressure Test Fitting Tool No. 6805-3 or 6805-4, or equivalent, depending on the thread size, into outlet port of proportioning valve. 6. Connect brake hydraulic line onto pressure test fitting on proportioning valve. 7. Install Pressure Gauge Set Tool No. C-4007-A, or equivalent, into test fitting and bleed air from pressure gauge hose. 8. Apply pressure to brake pedal until reading on proportioning valve inlet test fitting is appropriate, then check the pressure reading on the outlet test fitting. If the pressure on the outlet test fitting is not within specifications. 9. Install proportioning valve into master cylinder body until O-ring is seated, then torque proportioning valve to 30 ft. lbs. 10. Install brake tube onto proportioning valve and torque tube nut to 145 inch lbs. 11. Bleed brake line as outlined under Hydraulic Brake System/Service and Repair/Brake System Bleed. WITH ANTI-LOCK BRAKE SYSTEM Fig 39 Type 3 Proportioning Valve Location Fig 40 Type 3 Proportioning Valve Location 1. Road test vehicle to determine which rear wheel exhibits premature wheel skid. Refer to the images above to determine which proportioning valve needs to be tested. 2. Remove hydraulic brake line from proportioning valve to be tested, then remove valve from master cylinder outlet port. 3. Install Pressure Test Fitting Tool No. 6805-1 or 6805-2, or equivalent, depending on the thread size, into outlet port of master cylinder. 4. Install proportioning valve into pressure test fitting in master cylinder outlet port. 5. Install Pressure Test Fitting Tool No. 6805-3 or 6805-4, or equivalent, depending on the thread size, into outlet port of proportioning valve. 6. Connect brake hydraulic line onto pressure test fitting on proportioning valve. 7. Install Pressure Gauge Set Tool No. C-4007-A, or equivalent, into test fitting and bleed air from pressure gauge hose. 8. Apply pressure to brake pedal until reading on proportioning valve inlet test fitting is appropriate, then check the pressure reading on the outlet test fitting. If the pressure on the outlet test fitting is not within specifications, replace proportioning valve. 9. Install proportioning valve into master cylinder body until O-ring is seated, then torque proportioning valve to 30 ft. lbs. 10. Install brake tube onto proportioning valve and torque tube nut to 145 inch lbs. 11. Bleed brake line as outlined under Hydraulic Brake System/Service and Repair/Brake System Bleed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > Hydraulic Control Unit (HCU) Hydraulic Control Unit: Description and Operation Hydraulic Control Unit (HCU) The Hydraulic Control Unit (HCU) is located under the master cylinder. The HCU contains the following components for controlling brakes during ABS braking; four decay valves, four shuttle valves, two fluid sumps, a pump/motor and a relay box. Also attached to the HCU are rear brake proportioning valves and the six hydraulic tubes. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > Hydraulic Control Unit (HCU) > Page 4315 Hydraulic Control Unit: Description and Operation Hydraulic Modulator Circuit Operation CIRCUIT OPERATION The hydraulic modulator is used for the controlling of the brake system pressure to the wheels. The modulator is made up of four solenoids. Circuits involved are, B142 for the left front wheel, B143 for the right front wheel, B146 for the left rear wheel, and B148 for the right rear wheel. The solenoids use a common ground on the Z1 circuit. There are two Z1 circuits from the modulator. Both of these grounds terminate at the left headlamp ground, and are spliced in with the Anti-lock Brakes System (ABS) pump motor and the ABS system relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > Page 4316 Hydraulic Control Unit: Service and Repair The content of this article reflects the changes called out by TSB 05-07-94. REMOVAL 1. Disconnect battery ground cable and isolate cable. 2. Disconnect brake fluid level sensor electrical connector at base of master cylinder. 3. Disconnect primary and secondary brake tubes from master cylinder. Install plugs into master cylinder brake tube outlets. 4. Use a suitable brake cleaner to clean area where master cylinder attaches to power booster. 5. Pump brake pedal until it is firm. This will pump down the vacuum inside the power booster and prevent the booster from sucking in any contamination when removing the master cylinder. 6. Remove master cylinder to power booster retaining nuts, then slide master cylinder straight out. 7. Disconnect 6-way electrical connector from Hydraulic Control Unit (HCU) wiring harness and 10-way electrical connector from HCU relay box. 8. Remove primary and secondary master cylinder brake tubes from HCU. 9. Remove remaining brake tubes from proportioning valves and HCU outlet ports. 10. Raise and support vehicle. 11. Remove two bolts attaching HCU mounting bracket to side of front of frame rail. 12. Lower vehicle and remove bolts attaching HCU mounting bracket to top of frame rail. 13. Remove HCU and mounting bracket as an assembly from vehicle. INSTALLATION 1. Install HCU and mounting bracket as an assembly, on left frame rail of vehicle, aligning tabs on mounting bracket with holes in frame rail. 2. Install and loosely tighten bolt attaching HCU mounting bracket to top of frame rail. 3. Raise and support vehicle. 4. Install two bolts attaching HCU mounting bracket to side of front frame rail. Torque bolts to 16 ft. lbs. 5. Lower vehicle and torque bolt attaching HCU mounting bracket to top of frame rail to 9 ft. lbs. 6. Install four chassis brake tubes to HCU proportioning valves and outlet ports, torque brake tube nuts to 12 ft. lbs. 7. Install primary and secondary brake tubes from master cylinder onto HCU, then hand tighten tube nuts. 8. Connect electrical connectors to HCU. Fig 61 Power Brake Booster Vacuum Seal Removal 9. Using a small screwdriver, carefully remove vacuum seal from front of power brake booster. Do not attempt to pry seal out of master cylinder by inserting a tool between seal and power brake vacuum booster. 10. Remove old vacuum seal from master cylinder, if seal came out of power brake vacuum booster when master cylinder was removed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > Page 4317 Fig 62 Power Brake Booster Vacuum Seal Installation 11. Lubricate master cylinder push rod with Mopar Silicone Dielectric Compound - NO Substitutes. Then install new vacuum seal onto master cylinder push rod as shown. 12. Position master cylinder on studs of power brake booster, aligning push rods of power brake booster and master cylinder. 13. Install two master cylinder mounting nuts and torque to 21 ft. lbs. 14. Connect primary and secondary tubes to master cylinder and HCU. Torque brake tube nuts at master cylinder to 12 ft. lbs. and torque brake tube nuts at HCU to 15 ft. lbs. 15. Connect brake fluid level sensor electrical connector. 16. Bleed brake system as described in Hydraulic System/Service and Repair/Brake System Bleed procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls for Brake Master Cylinder: > 687 > Jun > 96 > Recall Master Cylinder Primary Piston Technical Service Bulletin # 687 Date: 960601 Recall - Master Cylinder Primary Piston No. 687 June, 1996 To: All Dodge and Chrysler-Plymouth Dealers Subject: Safety Recall # 687 -- Master Cylinder Primary Piston Models: ^ 1995 and 1996 Model Year Dodge Stratus, Chrysler Cirrus and 1996 Model Year Plymouth Breeze (JA) Vehicles (With and Without ABS) ^ 1995 and 1996 Model Year Dodge/Plymouth Neon (PL) Vehicles Equipped With Four Wheel Disc Brakes Without ABS The brake master cylinder rear piston seal may leak and cause a partial brake system loss. To correct this condition, the master cylinder primary piston assembly must be replaced. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory. and should perform this recall on vehicles in for service as determined by using DIAL System Function 70 or VIP. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by first class mail. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. All other dealers: Each Dodge and Chrysler-Plymouth dealer who does not receive a Vehicle List will receive a copy of this dealer recall notification letter by first class mail. DIAL System Function 70 and VIP All involved vehicles will be entered to DIAL System Function 70 and VIP at the time of recall implementation for dealer inquiry by VIN as needed. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Primary Piston Packages, Recall PN CBEA6871 for ABS equipped vehicles and CBGA6872 for NON-ABS equipped vehicles, to service about 25% of those vehicles. Each parts package contains the components as shown. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls for Brake Master Cylinder: > 687 > Jun > 96 > Recall Master Cylinder Primary Piston > Page 4326 Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing section for complete recall claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Master Cylinder Code Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls for Brake Master Cylinder: > 687 > Jun > 96 > Recall Master Cylinder Primary Piston > Page 4327 1. Inspect the front surface of the master cylinder for one of the following bottom codes as shown in figure 1 (the letter code is not important for this service): ^ ABS equipped JA vehicles (TWO master cylinder brake tubes) with a code of 3895; ^ NON-ABS equipped JA vehicles (FOUR master cylinder brake tubes) with a code of 3893; or ^ NON-ABS equipped PL vehicles (FOUR master cylinder brake tubes) with a code of 3815 If the master cylinder has one of the above four digit codes, replace the primary piston as instructed in Section B (verify that the vehicle has not already been repaired by using DIAL system function 70 or VIP). If the master cylinder has any other bottom code, no further action is required. B. Replace Master Cylinder Primary Piston 1. Clean master cylinder and attaching area of power brake booster with Mopar Glass Cleaner PN 4318014. 2. 2.4L engine equipped vehicles: Remove the air cleaner resonator/housing for greater access to master cylinder. 3. Speed control equipped vehicles: Remove mounting nuts and set speed control servo aside for greater access to master cylinder. 4. Disconnect wiring to master cylinder reservoir brake fluid level sensor. 5. Disconnect the primary and secondary brake tubes from master cylinder. Install provided plugs into master cylinder outlet ports and cap the brake tubes. Note: DO NOT drip brake fluid on painted surfaces as this may damage paint. 6. Remove the two nuts attaching the master cylinder to the brake booster. Slide the brake tube mounting bracket from the inboard master cylinder mounting stud and slide master cylinder off the brake booster mounting studs. 7. Drain brake fluid from the master cylinder reservoir. 8. Clamp master cylinder in a vice at the mounting flange area. Thoroughly clean master cylinder and reservoir with Mopar Glass Cleaner PN 4318014 and wipe with a clean cloth. Caution: DO NOT use this cleaner on any internal master cylinder components or on the master cylinder piston bore. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls for Brake Master Cylinder: > 687 > Jun > 96 > Recall Master Cylinder Primary Piston > Page 4328 9. ABS equipped vehicles only: Using a screw driver, pry away from the fluid level sensor and remove reservoir from master cylinder as shown in Figure 2. Be careful not to damage the fluid level switch and KEEP MASTER CYLINDER CLEAN AT ALL TIMES. 10. ABS equipped vehicles only: a. Remove and discard only the rear reservoir grommet and note which hole the primary piston retaining pin is in (Figure 3). b. Remove the master cylinder from the vice and turn the master cylinder upside down. Using the provided dowel rod, stroke the piston to allow the retaining pin to fall out, then remove the primary piston (Figure 4). Discard the old pin and piston. Note: If necessary, use a magnet while stroking the piston to remove the pin. Piston removal may require air pressure. Apply compressed air Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls for Brake Master Cylinder: > 687 > Jun > 96 > Recall Master Cylinder Primary Piston > Page 4329 (regulated to about 20 psi) to the primary outlet, while blocking the rear reservoir opening. Be sure to wear safety goggles. 11. NON-ABS equipped vehicles only: Using the supplied dowel rod1 stroke and hold the primary piston and remove the snap ring from the rear of the master cylinder, then remove the primary piston (Figure 5). Discard the old piston and snap ring. Caution: Be careful not to damage cylinder bore when using snap ring pliers. Note: Piston removal may require air pressure. Install the reservoir cap and apply compressed air (regulated to about 20 psi) to one primary outlet, while blocking the other primary outlet. Be sure to wear safety goggles. 12. With CLEAN HANDS, rinse the inside of the master cylinder and lubricate both of the seals on the new primary piston assembly with clean brake fluid conforming to DOT 3 specifications. Insert the new piston assembly spring end first. Note: ABS pistons must be installed with the piston slot in a vertical position to allow for piston pin installation (Figure 4). 13. ABS equipped vehicles only: a. Using supplied dowel rod, stroke and hold the primary piston approximately 3/4 inch. Insert new retaining pin into the same hole in master cylinder body that the original retaining pin was in (Figure 3). When inserted properly, the end of pin should be almost flush with master cylinder surface (Figure 6). b. Remove front reservoir grommet from the master cylinder body and discard. Verify that both primary and secondary piston pins are seated (end of pins are almost flush with surface as shown in figure 6). Lubricate two provided reservoir grommets with clean brake fluid and install grommets into the master cylinder body. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls for Brake Master Cylinder: > 687 > Jun > 96 > Recall Master Cylinder Primary Piston > Page 4330 c. Install reservoir onto master cylinder body using a rocking motion (fluid level sensor must be on outboard side when installed in vehicle). There must be no reservoir-to-grommet gaps, or grommet-to-master cylinder body gaps. If gaps exist, the piston pins may not be fully inserted (Figure 6). Caution: Make sure piston pins are inserted properly and that the grommets do not contact the ends of either pin. Failure to insert pins will cause brake drag. 14. NON-ABS equipped vehicles only: Using the supplied dowel rod, stroke and hold the primary piston assembly beyond the snap ring groove in the master cylinder body and install provided snap ring (Figure 5). Caution: Make sure snap ring is fully seated in groove. Be careful not to damage cylinder bore when using snap ring pliers. 15. Attach Miller Special Tool # 6802 bleed tubes to primary and secondary outlets and position tubes so the outlets will be submerged in brake fluid when reservoir is filled. Fill master cylinder reservoir with clean brake fluid conforming to DOT 3 specifications. Bench bleed master cylinder by using the provided dowel rod. Slowly depress pistons with dowel rod1 then allow pistons to return to the fully released position. Repeat this step several times after no air bubbles are expelled from the bleed tubes. This will insure all air is bled from the master cylinder (Figure 7). Note: DO NOT install the master cylinder without following the above bench bleeding procedure. When this procedure is followed, it is not necessary to bleed the entire vehicle brake system. 16. Remove the bleed tubes from the master cylinder outlet ports. Verify that brake fluid drips from both the primary and secondary outlet ports. Plug outlet ports with the supplied plugs, top off reservoir with brake fluid and install reservoir cap. Note: If brake fluid does not drip from the primary and/or secondary outlet ports, the master cylinder must be disassembled and the appropriate compensation port cleaned. On ABS master cylinders, no fluid dripping from an outlet port may also be caused by a missing/damaged piston pin or damaged piston center valve. 17. Install master cylinder assembly onto power brake booster studs. Align brake booster push rod with hole in master cylinder primary piston, then seat master cylinder against booster. Slide brake tube support bracket onto inboard mounting stud. Torque two attaching nuts to 250 in-lbs (28 N.m). 18. Remove master cylinder and brake tube plugs and attach brake tubes to master cylinder. Torque tube nuts to 145 in-lbs. (17 N.m). 19. Attach wiring connector to reservoir brake fluid level sensor. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls for Brake Master Cylinder: > 687 > Jun > 96 > Recall Master Cylinder Primary Piston > Page 4331 20. Verify proper brake warning lamp operation by removing the reservoir cap and using the provided dowel rod (make sure rod is clean) to push the float to the bottom of its travel (Figure 8). With the key in the ON position and the float at the bottom of its travel the warning light should be illuminated. Reinstall reservoir cap. 21. With engine off, pump brake pedal about 3-4 times until all vacuum in power brake booster is depleted. Apply light brake pedal pressure and hold for a minimum of 30 seconds. The brake pedal should remain firm. Apply heavy brake pedal pressure and hold for a minimum of 30 seconds. Again, the brake pedal should remain firm. If the brake pedal drops or is not firm during either of these tests, the master cylinder may either have a damaged piston assembly or it was not properly bled and must be repaired accordingly. 22. Speed control equipped vehicles: Install speed control servo and tighten nuts securely. 23. 2.4L engine equipped vehicles: Install air cleaner resonator/housing. 24. Verify that no brake fluid leaks exists and road test vehicle to assure proper brake operation. Owner Letter SAFETY RECALL To INSPECT AND REPAIR YOUR VEHICLE'S BRAKE MASTER CYLINDER Dear Chrysler Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1995 and 1996 Dodge Stratus, Dodge/Plymouth Neon, Chrysler Cirrus and 1996 Plymouth Breeze vehicles. The Problem is... The master cylinder rear piston seal on your vehicle (identified on the enclosed form), may leak and cause a partial brake system loss. The brake warning light will turn on to signal system impairment. If this warning is ignored, an increase in stopping distance could result in an accident. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will inspect your brake master cylinder and if necessary, replace the primary piston and seal assembly. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls for Brake Master Cylinder: > 687 > Jun > 96 > Recall Master Cylinder Primary Piston > Page 4332 written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls for Brake Master Cylinder: > NHTSA96V075000 > Apr > 96 > Recall 96V075000: Brake Master Cylinder Leak Brake Master Cylinder: Recalls Recall 96V075000: Brake Master Cylinder Leak THE BRAKE MASTER CYLINDER CAN LEAK BRAKE FLUID DUE TO A DAMAGED DOUBLE LIP REAR PISTON SEAL. BRAKE FLUID LEAKAGE CAN RESULT IN DIMINISHED EFFECTIVENESS OF ONE HALF OF THE SPLIT BRAKE SYSTEM. THE INSTRUMENT PANEL WARNING LIGHT(S) WILL SIGNAL SYSTEM IMPAIRMENT PRIOR TO PARTIAL BRAKE SYSTEM LOSS. DEALERS WILL REPLACE THE REAR BRAKE MASTER CYLINDER PISTON ASSEMBLY. SYSTEM: BRAKES; HYDRAULIC; MASTER BRAKE CYLINDER. INCLUDES NEON VEHICLES EQUIPPED WITH THE "ACR COMPETITION" PACKAGE ONLY. NOTE: OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME, SHOULD CONTACT CHRYSLER AT 1-800-853-1403. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston Technical Service Bulletin # 687 Date: 960601 Recall - Master Cylinder Primary Piston No. 687 June, 1996 To: All Dodge and Chrysler-Plymouth Dealers Subject: Safety Recall # 687 -- Master Cylinder Primary Piston Models: ^ 1995 and 1996 Model Year Dodge Stratus, Chrysler Cirrus and 1996 Model Year Plymouth Breeze (JA) Vehicles (With and Without ABS) ^ 1995 and 1996 Model Year Dodge/Plymouth Neon (PL) Vehicles Equipped With Four Wheel Disc Brakes Without ABS The brake master cylinder rear piston seal may leak and cause a partial brake system loss. To correct this condition, the master cylinder primary piston assembly must be replaced. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory. and should perform this recall on vehicles in for service as determined by using DIAL System Function 70 or VIP. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by first class mail. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. All other dealers: Each Dodge and Chrysler-Plymouth dealer who does not receive a Vehicle List will receive a copy of this dealer recall notification letter by first class mail. DIAL System Function 70 and VIP All involved vehicles will be entered to DIAL System Function 70 and VIP at the time of recall implementation for dealer inquiry by VIN as needed. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Primary Piston Packages, Recall PN CBEA6871 for ABS equipped vehicles and CBGA6872 for NON-ABS equipped vehicles, to service about 25% of those vehicles. Each parts package contains the components as shown. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 4342 Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing section for complete recall claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Master Cylinder Code Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 4343 1. Inspect the front surface of the master cylinder for one of the following bottom codes as shown in figure 1 (the letter code is not important for this service): ^ ABS equipped JA vehicles (TWO master cylinder brake tubes) with a code of 3895; ^ NON-ABS equipped JA vehicles (FOUR master cylinder brake tubes) with a code of 3893; or ^ NON-ABS equipped PL vehicles (FOUR master cylinder brake tubes) with a code of 3815 If the master cylinder has one of the above four digit codes, replace the primary piston as instructed in Section B (verify that the vehicle has not already been repaired by using DIAL system function 70 or VIP). If the master cylinder has any other bottom code, no further action is required. B. Replace Master Cylinder Primary Piston 1. Clean master cylinder and attaching area of power brake booster with Mopar Glass Cleaner PN 4318014. 2. 2.4L engine equipped vehicles: Remove the air cleaner resonator/housing for greater access to master cylinder. 3. Speed control equipped vehicles: Remove mounting nuts and set speed control servo aside for greater access to master cylinder. 4. Disconnect wiring to master cylinder reservoir brake fluid level sensor. 5. Disconnect the primary and secondary brake tubes from master cylinder. Install provided plugs into master cylinder outlet ports and cap the brake tubes. Note: DO NOT drip brake fluid on painted surfaces as this may damage paint. 6. Remove the two nuts attaching the master cylinder to the brake booster. Slide the brake tube mounting bracket from the inboard master cylinder mounting stud and slide master cylinder off the brake booster mounting studs. 7. Drain brake fluid from the master cylinder reservoir. 8. Clamp master cylinder in a vice at the mounting flange area. Thoroughly clean master cylinder and reservoir with Mopar Glass Cleaner PN 4318014 and wipe with a clean cloth. Caution: DO NOT use this cleaner on any internal master cylinder components or on the master cylinder piston bore. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 4344 9. ABS equipped vehicles only: Using a screw driver, pry away from the fluid level sensor and remove reservoir from master cylinder as shown in Figure 2. Be careful not to damage the fluid level switch and KEEP MASTER CYLINDER CLEAN AT ALL TIMES. 10. ABS equipped vehicles only: a. Remove and discard only the rear reservoir grommet and note which hole the primary piston retaining pin is in (Figure 3). b. Remove the master cylinder from the vice and turn the master cylinder upside down. Using the provided dowel rod, stroke the piston to allow the retaining pin to fall out, then remove the primary piston (Figure 4). Discard the old pin and piston. Note: If necessary, use a magnet while stroking the piston to remove the pin. Piston removal may require air pressure. Apply compressed air Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 4345 (regulated to about 20 psi) to the primary outlet, while blocking the rear reservoir opening. Be sure to wear safety goggles. 11. NON-ABS equipped vehicles only: Using the supplied dowel rod1 stroke and hold the primary piston and remove the snap ring from the rear of the master cylinder, then remove the primary piston (Figure 5). Discard the old piston and snap ring. Caution: Be careful not to damage cylinder bore when using snap ring pliers. Note: Piston removal may require air pressure. Install the reservoir cap and apply compressed air (regulated to about 20 psi) to one primary outlet, while blocking the other primary outlet. Be sure to wear safety goggles. 12. With CLEAN HANDS, rinse the inside of the master cylinder and lubricate both of the seals on the new primary piston assembly with clean brake fluid conforming to DOT 3 specifications. Insert the new piston assembly spring end first. Note: ABS pistons must be installed with the piston slot in a vertical position to allow for piston pin installation (Figure 4). 13. ABS equipped vehicles only: a. Using supplied dowel rod, stroke and hold the primary piston approximately 3/4 inch. Insert new retaining pin into the same hole in master cylinder body that the original retaining pin was in (Figure 3). When inserted properly, the end of pin should be almost flush with master cylinder surface (Figure 6). b. Remove front reservoir grommet from the master cylinder body and discard. Verify that both primary and secondary piston pins are seated (end of pins are almost flush with surface as shown in figure 6). Lubricate two provided reservoir grommets with clean brake fluid and install grommets into the master cylinder body. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 4346 c. Install reservoir onto master cylinder body using a rocking motion (fluid level sensor must be on outboard side when installed in vehicle). There must be no reservoir-to-grommet gaps, or grommet-to-master cylinder body gaps. If gaps exist, the piston pins may not be fully inserted (Figure 6). Caution: Make sure piston pins are inserted properly and that the grommets do not contact the ends of either pin. Failure to insert pins will cause brake drag. 14. NON-ABS equipped vehicles only: Using the supplied dowel rod, stroke and hold the primary piston assembly beyond the snap ring groove in the master cylinder body and install provided snap ring (Figure 5). Caution: Make sure snap ring is fully seated in groove. Be careful not to damage cylinder bore when using snap ring pliers. 15. Attach Miller Special Tool # 6802 bleed tubes to primary and secondary outlets and position tubes so the outlets will be submerged in brake fluid when reservoir is filled. Fill master cylinder reservoir with clean brake fluid conforming to DOT 3 specifications. Bench bleed master cylinder by using the provided dowel rod. Slowly depress pistons with dowel rod1 then allow pistons to return to the fully released position. Repeat this step several times after no air bubbles are expelled from the bleed tubes. This will insure all air is bled from the master cylinder (Figure 7). Note: DO NOT install the master cylinder without following the above bench bleeding procedure. When this procedure is followed, it is not necessary to bleed the entire vehicle brake system. 16. Remove the bleed tubes from the master cylinder outlet ports. Verify that brake fluid drips from both the primary and secondary outlet ports. Plug outlet ports with the supplied plugs, top off reservoir with brake fluid and install reservoir cap. Note: If brake fluid does not drip from the primary and/or secondary outlet ports, the master cylinder must be disassembled and the appropriate compensation port cleaned. On ABS master cylinders, no fluid dripping from an outlet port may also be caused by a missing/damaged piston pin or damaged piston center valve. 17. Install master cylinder assembly onto power brake booster studs. Align brake booster push rod with hole in master cylinder primary piston, then seat master cylinder against booster. Slide brake tube support bracket onto inboard mounting stud. Torque two attaching nuts to 250 in-lbs (28 N.m). 18. Remove master cylinder and brake tube plugs and attach brake tubes to master cylinder. Torque tube nuts to 145 in-lbs. (17 N.m). 19. Attach wiring connector to reservoir brake fluid level sensor. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 4347 20. Verify proper brake warning lamp operation by removing the reservoir cap and using the provided dowel rod (make sure rod is clean) to push the float to the bottom of its travel (Figure 8). With the key in the ON position and the float at the bottom of its travel the warning light should be illuminated. Reinstall reservoir cap. 21. With engine off, pump brake pedal about 3-4 times until all vacuum in power brake booster is depleted. Apply light brake pedal pressure and hold for a minimum of 30 seconds. The brake pedal should remain firm. Apply heavy brake pedal pressure and hold for a minimum of 30 seconds. Again, the brake pedal should remain firm. If the brake pedal drops or is not firm during either of these tests, the master cylinder may either have a damaged piston assembly or it was not properly bled and must be repaired accordingly. 22. Speed control equipped vehicles: Install speed control servo and tighten nuts securely. 23. 2.4L engine equipped vehicles: Install air cleaner resonator/housing. 24. Verify that no brake fluid leaks exists and road test vehicle to assure proper brake operation. Owner Letter SAFETY RECALL To INSPECT AND REPAIR YOUR VEHICLE'S BRAKE MASTER CYLINDER Dear Chrysler Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1995 and 1996 Dodge Stratus, Dodge/Plymouth Neon, Chrysler Cirrus and 1996 Plymouth Breeze vehicles. The Problem is... The master cylinder rear piston seal on your vehicle (identified on the enclosed form), may leak and cause a partial brake system loss. The brake warning light will turn on to signal system impairment. If this warning is ignored, an increase in stopping distance could result in an accident. What Chrysler and your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will inspect your brake master cylinder and if necessary, replace the primary piston and seal assembly. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > 687 > Jun > 96 > Recall - Master Cylinder Primary Piston > Page 4348 written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > NHTSA96V075000 > Apr > 96 > Recall 96V075000: Brake Master Cylinder Leak Brake Master Cylinder: All Technical Service Bulletins Recall 96V075000: Brake Master Cylinder Leak THE BRAKE MASTER CYLINDER CAN LEAK BRAKE FLUID DUE TO A DAMAGED DOUBLE LIP REAR PISTON SEAL. BRAKE FLUID LEAKAGE CAN RESULT IN DIMINISHED EFFECTIVENESS OF ONE HALF OF THE SPLIT BRAKE SYSTEM. THE INSTRUMENT PANEL WARNING LIGHT(S) WILL SIGNAL SYSTEM IMPAIRMENT PRIOR TO PARTIAL BRAKE SYSTEM LOSS. DEALERS WILL REPLACE THE REAR BRAKE MASTER CYLINDER PISTON ASSEMBLY. SYSTEM: BRAKES; HYDRAULIC; MASTER BRAKE CYLINDER. INCLUDES NEON VEHICLES EQUIPPED WITH THE "ACR COMPETITION" PACKAGE ONLY. NOTE: OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME, SHOULD CONTACT CHRYSLER AT 1-800-853-1403. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Page 4353 Brake Master Cylinder: Specifications Master Cylinder Bore Dia. Inch ............................................................................................................ ........................................................................ 0.875 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > With Antilock Brakes Brake Master Cylinder: Description and Operation With Antilock Brakes This system uses a modified master cylinder and power brake booster assembly. The master cylinder primary and secondary outputs go directly to the Hydraulic Control Unit (HCU). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > With Antilock Brakes > Page 4356 Brake Master Cylinder: Description and Operation Without Antilock Brakes This type of master cylinder, utilizes screw-in proportioning valves at the master cylinder instead of a combination valve. With this new design, the chassis brake tubes connect directly from the master cylinder to the brake flex hose. Vehicles not equipped with Antilock Brake System (ABS) use a standard compensating port design, while vehicles equipped with ABS use a center valve design. Fig 4 Type 3 Master Cylinder. Less ABS In addition, the non-ABS master cylinders are a four outlet design with two screw-in proportioning valves attached directly to the inboard side of the master cylinder housing. Fig 5 Type 3 Master Cylinder. With ABS The ABS master cylinders are a two outlet design with the screw-in proportioning valves attached to the ABS Hydraulic Control Unit (HCU). Vehicles equipped with rear drum brakes use a master cylinder with a 21 mm bore, while vehicles equipped with rear disc brakes use a 7/8 inch bore master cylinder. The body of the master cylinder is an anodized aluminum casting. It has a machined bore to accept the master cylinder piston and threaded ports with seats for hydraulic brake line connections. The brake fluid reservoir assembly is made of polypropylene plastic. The only serviceable component on both master cylinders are the reservoir and the sealing grommets. Neither of the master cylinder assemblies can be serviced, and must be replaced as an assembly. On non-ABS master cylinders, the primary outlet ports supply hydraulic pressure to the left front and right rear brakes. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > With Antilock Brakes > Page 4357 Fig 6 Type 3 Primary And Secondary Output Ports. Less ABS The secondary outlet ports supply hydraulic pressure to the right front and left rear brakes. Fig 7 Type 3 Primary And Secondary Output Ports. With ABS On ABS master cylinders, the primary outlet ports supply hydraulic pressure to the right front and left rear brakes. the secondary outlet ports supply hydraulic pressure to the left front and right rear brakes. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Brake Master Cylinder: Service and Repair Master Cylinder Bleeding Notes and Precautions Combination valves containing brake warning or pressure differential type valves are self-centering. They will reset after hydraulic system pressure is equalized, and by doing the following: Upon completion of bleeding the hydraulic system, depress the brake pedal with moderate force. The brake warning lamp will turn off when the switch is re-centered. Bench Bleeding When replacing or overhauling a master cylinder, it is advisable to bleed it before installing it on the car. Bleeding Tubes Attached To Master Cylinder Without ABS Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4360 Bleeding Master Cylinder PROCEDURE 1. Clamp the master cylinder in a vise. Attach bleeding tubes, Special Tool 6802, or equivalent to the master cylinder outlet ports. Position bleeding tubes so the outlets of the bleeding tubes will be below the surface of the brake fluid when reservoir is filled to proper level. 2. Fill brake fluid reservoir with brake fluid conforming to DOT 3 specifications such as Mopar or an equivalent. 3. Using a wooden dowel. Depress push rod slowly, and then allow pistons to return to the released position. Continue to repeat this step several times after no more air bubbles are expelled from bleed tubes to ensure all air is bled from the master cylinder. 4. Remove bleeding tubes from master cylinder outlet ports, plug outlet ports and install fill cap on reservoir. 5. Remove master cylinder from vise and install master cylinder into vehicle. 6. Bleed the entire hydraulic system. Manual Bleeding Master cylinders may be bled manually or by pressure bleeding. It is recommended that the master cylinder be bled before bleeding the wheel cylinders and calipers. CAUTION: Use the specified brake fluid. Don't use a mixture of the specified brake fluid and another non-specified fluid. Specified brake fluid: MOPAR DOT 3 or DOT 4 MANUAL BLEEDING 1. Ensure master cylinder reservoir is full. Add suitable brake fluid as needed, and securely reinstall the master cylinder cap. 2. Position a drain pan under the master cylinder. 3. Have an assistant depress the brake pedal with a slow even pressure and hold it. Do not depress brake pedal fully to the end of the master cylinder stroke. This may cause damage to the master cylinder. 4. Loosen the brake lines, or bleeder valves if equipped, at the master cylinder. Watch for air bubbles in the fluid and listen for air escaping from the system. While bleeding the system, recheck brake fluid supply in the master cylinder often so as not to allow the master cylinder to run dry. 5. With brake pedal still depressed, tighten the brake lines or bleeder valves. 6. Bleed the master cylinder until all air is removed. Upon completion of bleeding, proceed as follows: a. Ensure the master cylinder reservoir is full. Add suitable brake fluid as needed, and securely reinstall the master cylinder cap. b. Ensure brake pedal is firm, and braking operation is proper. Pressure Bleeding Master cylinders may be bled manually or by pressure bleeding. It is recommended that the master cylinder be bled before bleeding the wheel cylinders and calipers. PRESSURE BLEEDING 1. Ensure master cylinder reservoir is full. Add suitable brake fluid as needed. 2. Install pressure bleeder according to manufacturer specifications. 3. Position a drain pan under the master cylinder. 4. Loosen brake lines, or bleeder valves if equipped, at the master cylinder. Watch for air bubbles in the fluid and listen for air escaping from the system. 5. Retighten brake lines or bleeder valves. 6. Bleed the master cylinder until all air is removed. Upon completion of bleeding, proceed as follows: a. Ensure the master cylinder reservoir is full. Add suitable brake fluid as needed, and securely reinstall the master cylinder cap. b. Ensure brake pedal is firm, and braking operation is proper. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4361 Brake Master Cylinder: Service and Repair Master Cylinder Replacement The content of this article reflects the changes called out by TSB 05-07-94. REMOVAL When replacing master cylinder on models equipped with ABS, vacuum in power booster must be pumped down before removing master cylinder to prevent booster from sucking in any contamination. This can be done by pumping the brake pedal until it is firm, with the ignition off. 1. On models equipped with ABS, ensure engine is not running and brake pedal has been pumped until firm. 2. On all models, remove wiring harness connector from brake fluid level sensor mounted on fluid reservoir. 3. Disconnect the primary and secondary brake tubes from master cylinder housing. Install suitable plugs at all open brake tube outlets on master cylinder assembly. 4. On models equipped with ABS, clean area where master cylinder attaches to power brake vacuum booster using a suitable brake cleaner. 5. On all models, remove nuts attaching master cylinder to power brake vacuum booster. 6. Slide master cylinder forward out of power brake vacuum booster. Fig 18 Type 3 Vacuum Seal Removed. Neon Models Equipped With ABS 7. On models equipped with ABS, the vacuum seal in the front of the power brake vacuum booster must be replaced. Remove vacuum seal in front of power brake vacuum booster by carefully inserting a suitable, small, screwdriver between master cylinder push rod and vacuum seal and prying seal out of booster. Do not attempt to pry seal out by inserting screwdriver between seal and booster. INSTALLATION 1. On models equipped with ABS, install new vacuum seal as follows: a. Lubricate master cylinder push rod using Mopar Silicone Dielectric Compound - NO Substitutes. Fig 19 Type 3 Vacuum Seal Installation. Neon Models Equipped With ABS Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4362 Fig 20 Type 3 Vacuum Seal Seating. Neon Models Equipped With ABS b. Slide vacuum seal onto master cylinder push rod with notches on seal pointing toward and seated against master cylinder housing. 2. On all models, slide master cylinder assembly into power brake vacuum booster and position on mounting studs. 3. Install mounting nuts and torque to 250 in. lbs. 4. Connect brake tubes to master cylinder primary and secondary ports and torque tube nuts to 145 in. lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4363 Brake Master Cylinder: Service and Repair Master Cylinder Overhaul When disassembling the master cylinder, note the position of all parts as they are removed for proper installation. When disassembled, wash all parts in denatured alcohol or clean brake fluid only. Use an air hose to blow out all passages, orifices and valve holes. Air dry and place parts on clean paper or lint-free cloth. Inspect master cylinder bore for scoring, rust, pitting or etching. Any of these conditions will require replacement of the housing. Never hone the bore of the master cylinder as this will remove the anodized surface. Inspect master cylinder pistons for scoring, pitting or distortion. Replace piston if any of these conditions exist. If either the master cylinder housing or piston is replaced, clean the new parts with denatured alcohol or clean brake fluid, and blow out all passages with air hose. Examine reservoirs for foreign matter and check all passages for restrictions. If there is any indication of contamination or evidence of corrosion, service the hydraulic system as needed, and flush the entire system as described under Hydraulic System / Service and Repair / Brake System Bleed. When reassembling the master cylinder, use all parts contained in the repair kit. Dip all component parts in clean brake fluid, and place them on a clean surface. To prevent faulty operation, when installing seals inspect through side outlet of the dual master cylinder housing to make certain cup lips do not hang up on edge of hole or turn back. A piece of 3/16 inch rod with an end rounded off will be helpful in guiding cups past the hole. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 4364 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement REMOVAL 1. Clean master cylinder housing and brake fluid reservoir. 2. Remove reservoir cap and remove as much brake fluid as possible using suitable syringe or similar tool. Removing Fluid Reservoir From Master Cylinder 3. Rock reservoir from side to side while pulling upward to remove from master cylinder housing. Do not pry off using a tool as damage to reservoir may result. 4. Remove reservoir grommets from master cylinder housing. INSTALLATION 1. Install new reservoir grommets in master cylinder housing. 2. Lubricate reservoir mounting area with fresh, clean brake fluid. 3. Install reservoir by pushing downward and rocking from side to side. Ensure reservoir is fully seated. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cylinder: > 050596 > May > 96 > Rear Brakes Cyclic Chirping Noise Wheel Cylinder: Customer Interest Rear Brakes - Cyclic Chirping Noise NO: 05-05-96 GROUP: Brakes DATE: May 5, 1996 SUBJECT: Rear Brake Cyclic Chirp NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-04-96 DATED MARCH 8, 1996 AND TECHNICAL SERVICE BULLETIN 05-06-95 DATED MAY 19, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE 1996 SEBRING CONVERTIBLE HAS BEEN ADDED AND THE "PROTECT -A- CUP", LUBE IS NOW AVAILABLE THRU MOPAR PARTS. ALL CHANGES ARE MARKED WITH **ASTERISKS** MODELS: 1995 - 1996 (PL) Neon 1996 (JX) Sebring Convertible** SYMPTOM/CONDITION: A cyclic chirp noise from the rear of the vehicle during medium to light brake application, at low speeds (20 mph or less) on vehicles equipped with rear drum brakes. The noise can be related to the speed at which the tire turns (one squeak/squawk per revolution of the tire). As the vehicle slows, during the brake application, the noise will occur at a slower rate. **NOTE: THIS REPAIR HAS NO EFFECT ON THE REAR BRAKE HOWL NOISE THAT MAY OCCUR ON NEONS, AT THE END OF THE STOP. THE REAR BRAKE HOWL NOISE IS COVERED IN A SEPARATE TECHNICAL SERVICE BULLETIN.** PARTS REQUIRED: 1 4883068 "Protect -A- Cup" (Lube Cap) REPAIR PROCEDURE: This bulletin involves the installation of 4 drops of the "Protect -A- Cup" lubricant into each rear wheel cylinder. 1. Raise car on suitable hoist and remove rear wheels. 2. Remove rear brake drum retaining clips (1 per side) and remove rear brake drums. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cylinder: > 050596 > May > 96 > Rear Brakes Cyclic Chirping Noise > Page 4373 3. Peel back the top edge of the wheel cylinder boot and put four drops of the "Protect - A - Cup" fluid into the wheel cylinder. This fluid acts as a lubricant between the wheel cylinder the piston and the wheel cylinder boot (Figure 1). 4. Install the wheel cylinder boot onto the wheel cylinder casting. Make sure that the boot seats properly on the casting lip all the way around the wheel cylinder. 5. Repeat the process for the other three boots (two per brake). CAUTION: THE "PROTECT -A- CUP" ASSEMBLY FLUID USED TO ADDRESS THE CYCLIC CHIRP NOISE SHOULD NOT BE USED FOR ANY PURPOSE IN THE VEHICLE1S BRAKE SYSTEM OTHER THAN AS DESCRIBED IN THIS TSB. 6. Wipe any spilled fluid from the outside of the wheel cylinder as well as any other brake parts including the linings. 7. Install the brake drums, retaining clips and rear wheels. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-90-50-93 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cylinder: > 050596 > May > 96 > Rear Brakes - Cyclic Chirping Noise Wheel Cylinder: All Technical Service Bulletins Rear Brakes - Cyclic Chirping Noise NO: 05-05-96 GROUP: Brakes DATE: May 5, 1996 SUBJECT: Rear Brake Cyclic Chirp NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-04-96 DATED MARCH 8, 1996 AND TECHNICAL SERVICE BULLETIN 05-06-95 DATED MAY 19, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE 1996 SEBRING CONVERTIBLE HAS BEEN ADDED AND THE "PROTECT -A- CUP", LUBE IS NOW AVAILABLE THRU MOPAR PARTS. ALL CHANGES ARE MARKED WITH **ASTERISKS** MODELS: 1995 - 1996 (PL) Neon 1996 (JX) Sebring Convertible** SYMPTOM/CONDITION: A cyclic chirp noise from the rear of the vehicle during medium to light brake application, at low speeds (20 mph or less) on vehicles equipped with rear drum brakes. The noise can be related to the speed at which the tire turns (one squeak/squawk per revolution of the tire). As the vehicle slows, during the brake application, the noise will occur at a slower rate. **NOTE: THIS REPAIR HAS NO EFFECT ON THE REAR BRAKE HOWL NOISE THAT MAY OCCUR ON NEONS, AT THE END OF THE STOP. THE REAR BRAKE HOWL NOISE IS COVERED IN A SEPARATE TECHNICAL SERVICE BULLETIN.** PARTS REQUIRED: 1 4883068 "Protect -A- Cup" (Lube Cap) REPAIR PROCEDURE: This bulletin involves the installation of 4 drops of the "Protect -A- Cup" lubricant into each rear wheel cylinder. 1. Raise car on suitable hoist and remove rear wheels. 2. Remove rear brake drum retaining clips (1 per side) and remove rear brake drums. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cylinder: > 050596 > May > 96 > Rear Brakes - Cyclic Chirping Noise > Page 4379 3. Peel back the top edge of the wheel cylinder boot and put four drops of the "Protect - A - Cup" fluid into the wheel cylinder. This fluid acts as a lubricant between the wheel cylinder the piston and the wheel cylinder boot (Figure 1). 4. Install the wheel cylinder boot onto the wheel cylinder casting. Make sure that the boot seats properly on the casting lip all the way around the wheel cylinder. 5. Repeat the process for the other three boots (two per brake). CAUTION: THE "PROTECT -A- CUP" ASSEMBLY FLUID USED TO ADDRESS THE CYCLIC CHIRP NOISE SHOULD NOT BE USED FOR ANY PURPOSE IN THE VEHICLE1S BRAKE SYSTEM OTHER THAN AS DESCRIBED IN THIS TSB. 6. Wipe any spilled fluid from the outside of the wheel cylinder as well as any other brake parts including the linings. 7. Install the brake drums, retaining clips and rear wheels. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-90-50-93 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 4380 Wheel Cylinder: Specifications Bearing Retainer Bolts 160 ft.lb Brake Line Fittings 12 ft.lb Support Plate To Rear Axle 85 ft.lb Wheel Cylinder Bleed Screws 6 ft.lb Wheel Cylinder To Backing Plate 6 ft.lb Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation REMOVAL 1. Remove wheel, drum and brake shoes. 2. Loosen brake line fitting at wheel cylinder. Do not pull metal line away from cylinder. 3. Remove screws holding cylinder to backing plate. 4. Separate wheel cylinder from brake line and backing plate by pulling the cylinder outward and away from backing plate. INSTALLATION 1. Wipe end of hydraulic line to remove any foreign matter. 2. Position wheel cylinder to backing plate. Install brake line to cylinder and start connecting fitting. 3. Secure wheel cylinder to backing plate, then complete tightening of brake line fitting. 4. Install brake shoes, drum and wheel. 5. Bleed system as outlined previously, and adjust brakes. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4383 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul Note position of all parts as they are removed for proper installation. DISASSEMBLE Fig 28 Disassembled View Of Typical Wheel Cylinder 1. Remove boots, pistons, cups and spring from wheel cylinder. 2. Wipe cylinder walls with denatured alcohol or clean brake fluid. 3. Examine cylinder bore. A scored bore may be honed providing the bore diameter is not increased more than 0.005 inch. Replace as necessary. 4. Check pistons for wear or damage. Replace as necessary. ASSEMBLE 1. Before assembling, wash hands with soap and water so as not to contaminate rubber parts. 2. Use all parts contained in repair kit. Lubricate cylinder wall and rubber cups with brake fluid. 3. Properly install spring, cups, pistons and boots in housing. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Testing and Inspection Parking Brake Cable: Testing and Inspection Inspect parking brake cable ends, inspect cables for kinks, fraying and elongation, and replace as necessary. TIP: Use a small hose clamp to compress clamp where it enters backing plate to remove. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal Parking Brake Cable: Service and Repair Cable Removal NOTE: Remove only one rear park brake cable from rear brakes at a time. Failure to do so will result in high efforts required to connect park brake cables to equalizer or park brake lever at rear wheel brakes. PROCEDURE Attaching Screws At Rear Of Center Console With Out Arm Rest Attaching Screws At Rear Of Center Console With Arm Rest 1. Remove screws attaching rear of center console assembly to floor pan of vehicle. Attaching Screws At Front Of Center Console 2. Remove the 2 screws located in cup holders attaching front of center console to console bracket. 3. Raise park brake lever as high as it will go for the clearance required to remove the center console. 4. Remove center console assembly from vehicle. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4390 WARNING: WHEN REPAIRS TO THE PARK BRAKE HAND LEVER ASSEMBLY OR CABLES IS REQUIRED, THE AUTO ADJUSTER MUST BE PRELOADED AND LOCKED OUT. 5. Lower park brake lever handle. Locking Pin Installed In Park Brake Lever 6. Grasp park lever output cable by hand and pull rearward. Continue pulling on cable until a 3/16 in. drill bit can be inserted into handle and sector gear of park brake mechanism. This will lock the park brake mechanism and take tension off park brake cables. Park Brake Cables At Equalizer 7. Remove rear park brake cables from the park brake cable equalizer. 8. Remove rear seat cushion from vehicle. Rear Door Sill Scuff Plates Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4391 9. Remove scuff plates from right and left rear door sills. Scuff plates are attached to door sills using clips on bottom of scuff plates. Remove by carefully prying scuff plate retaining clips out of door sills. 10. Fold rear carpeting forward to expose park brake cables. Compressing Park Brake Cable Retaining Tabs 11. Install the box end of a 1/2 in. wrench over the park brake cable retainer as indicated. This will compress tabs on park brake cable retainer, allowing cable to be removed from console bracket. From under carpet, grasp park brake cable housing and pull cable straight out of console bracket. 12. Raise vehicle on jackstands or centered on a frame contact type hoist. 13. Remove rear wheel and tire assembly. Rear Brake Drum Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4392 Rear Brake Rotor 14. On vehicles equipped with rear drum brakes, remove brake drum from rear hub/bearing assembly. On vehicles equipped with rear disc brakes, remove disc brake caliper from disc brake adapter, and then remove rotor from hub/ bearing assembly. Rear Hub/Bearing Dust Cap Removal 15. Remove dust cap from rear hub/ bearing assembly. Hub/Bearing Assembly Retaining Nut 16. Remove hub/bearing assembly retaining nut. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4393 Hub/Bearing Removal From Spindle (Drum Brakes Shown) 17. Remove the rear hub/bearing assembly from the rear spindle. Park Brake Cable Attachment To Actuating Lever Brake Adjustment Lever Actuating Spring 18. On vehicles equipped with rear drum brakes, remove park brake cable from park brake actuating lever. Then remove the actuating spring between brake shoe adjustment lever and brake shoe assembly. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4394 Parking Brake Shoe Assemblies Parking Brake Actuator Lever 19. On vehicles equipped with rear disc brakes, remove brake shoe assemblies from rear disc brake adapter. Then remove parking brake actuating lever from the park brake cable. Park Brake Cable Removal From Brake Support Plate 20. On vehicles equipped with rear drum brakes, remove park brake cable from rear brake support plate. Park brake cable is removed from brake support plate using a 1/2 in. wrench as shown above to compress locking tabs on park brake cable retainer. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4395 Park Brake Cable Removal From Disc Brake Adapter 21. On vehicles equipped with rear disc brakes, remove park brake cable from rear disc brake adapter. Park brake cable is removed from disc brake adapter using a screwdriver as shown to compress locking tabs on park brake cable retainer. Park Brake Cable Routing Bracket 22. Remove park brake cable routing bracket from vehicle frame rail. Park Brake Cable Seal At Floor Pan 23. Remove park brake cable and sealing grommet from floor pan of vehicle. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4396 Parking Brake Cable: Service and Repair Cable Installation PROCEDURE 1. Install park brake cable into floor pan of vehicle making sure sealing grommet is installed in floor pan as far as possible to insure proper seal. 2. Install park brake cable into brake support plate or rear disc brake adapter. Be sure locking tabs on cable retainer are expanded to ensure park brake cable is securely held in support plate or adapter. Park Brake Cable Routing Bracket 3. Install park brake cable routing bracket on frame rail. Install and securely tighten routing bracket attaching bolt. Park Brake Cable Attachment To Actuating Lever Brake Adjustment Lever Actuating Spring 4. On vehicles equipped with rear drum brakes, install park brake cable on park brake cable actuating lever. Then install actuating spring between brake shoe assembly and brake adjustment lever. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4397 Parking Brake Shoe Assemblies Parking Brake Actuator Lever 5. On vehicles equipped with rear disc brakes, install park brake shoes actuator lever on park brake cable. Then install park brake shoe assemblies on disc brake adapter. 6. Install the hub/bearing assembly on the rear spindle. Then install A NEW rear hub/bearing assembly retaining nut. Torque hub/bearing assembly retaining nut to 217 Nm (160 ft. lbs.). 7. Install hub/bearing assembly dust cap, using a soft faced hammer. 8. On drum brake equipped vehicles, install rear brake drum on hub/bearing assembly. On vehicles equipped with rear disc brakes, install rotor on hub/ bearing assembly. Rear Caliper Guide Pin Bolts 9. On disc brake equipped vehicles install disc brake caliper on disc brake adapter. Install the 2 caliper guide pin bolts and torque to 22 Nm (192 in. lbs.). Refer to Disc Brake Caliper Service and Repair for installation procedure. 10. Install rear wheel and tire assembly on vehicle, tighten all wheel stud nuts in crisscross pattern to one-half specified torque. Then repeat pattern, fully tightening stud nuts to 109 - 150 Nm (80 - 110 ft. lbs.). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4398 11. Lower vehicle. Seal Grommet Installation In Floor Pan 12. Grasp park brake cable to floor pan seal grommet by hand, and pull it into floor pan to ensure seal grommet is fully seated into floor pan. Park Brake Cable Installed In Retaining Bracket 13. Route park brake cable under carpeting and up to park brake cable retaining bracket on floor pan. Then install park brake cable into retaining bracket. Be sure tabs on park brake cable retainer, have expanded out to hold park brake cable in retaining bracket. Park Brake Cables At Equalizer 14. Install rear park brake cables into equalizer on park brake lever cable. 15. Reposition rear carpeting. 16. Install both rear door sill plate scuff moldings, by snapping them onto rear door sills. 17. Install lower rear seat cushion. Be sure lower seat cushion is fully installed in retainers on floor pan of vehicle. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable Removal > Page 4399 Removing Lockout Pin From Park Brake Lever 18. Firmly grasp park brake lever locking pin (3/16 in. drill bit) and quickly remove it from the park brake lever mechanism. This will allow the park brake lever mechanism to correctly adjust the park brake cables. 19. Cycle park brake lever ounce to position park brake cables. Then return the park brake lever to its released position. Check the rear wheels of the vehicle, they should rotate freely without dragging. 20. Apply park brake to full engagement. 21. Install center console assembly. 22. Install the center console assembly attaching screws. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair Parking Brake Shoe: Service and Repair 1. Raise and support vehicle. 2. Remove rear wheel and tire assembly. 3. Remove caliper from rotor as described under Brake Pad/Service and Repair. 4. Remove rotor from hub. 5. Remove grease cap, cotter pin, locknut, retaining nut, washer, hub and bearings. 6. Using a suitable tool, remove forward hold-down clip. 7. Turn adjuster wheel until adjuster is at its shortest length, then remove adjuster assembly. 8. Remove upper shoe to shoe spring. 9. Pull front shoe away from anchor, then remove front shoe and lower spring. 10. Using a suitable tool, remove rear hold-down clip and shoe. 11. Reverse procedure to install noting the following: a. Adjust shoe diameter to 6.75 inches. b. Tighten wheel bearing adjusting nut to specifications while rotating hub to seat bearings, back off adjusting nut 1/4 turn, then tighten finger tight. c. Align nut-to-spindle holes for cotter pin insertion. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Testing and Inspection Parking Brake Warning Switch: Testing and Inspection In the START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) to circuit A41. A 30 Amp fuse protects circuits A1 and A41. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation Vacuum Brake Booster: Description and Operation DESCRIPTION Fig 1 Bendix Single Diaphragm Power Brake Unit Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 4410 Fig 2 Bendix Tandem Diaphragm Power Brake These units are of the vacuum suspended type. Some units are of the single diaphragm type, while others are of the tandem diaphragm type. Both single piston and double piston or split system type master cylinders are used. The vacuum suspended diaphragm type units utilize engine manifold vacuum and atmospheric pressure for its power. It consists of three basic Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 4411 elements combined into a single power unit. The three basic elements of the single diaphragm type are: 1. A vacuum power section which includes a front and rear shell, a power diaphragm, a return spring and a pushrod. 2. A control valve, integral with the power diaphragm and connected through a valve rod to the brake pedal, controls the degree of brake application or release in accordance with the pressure applied to the brake pedal. 3. A hydraulic master cylinder, attached to the vacuum power section which contains all the elements of the conventional brake master cylinder (except for the pushrod), supplies fluid under pressure to the wheel brakes in proportion to the pressure applied to the brake pedal. OPERATION Upon application of the brakes, the valve rod and plunger move to the left in the power diaphragm to close the vacuum port and open the atmospheric port to admit air through the air cleaner and valve at the rear diaphragm chamber. With vacuum present in the rear chamber, a force is developed to move the power diaphragm, hydraulic pushrod and hydraulic piston or pistons to close the compensating port or ports and force fluid under pressure through the residual check valve or valves and lines into the front and rear wheel cylinders to actuate the brakes. As pressure is developed within the master cylinder a counter force acting through the hydraulic pushrod and reaction disc against the vacuum power diaphragm and valve plunger sets up a reaction force opposing the force applied to the valve rod and plunger. This reaction force tends to close the atmospheric port and reopen the vacuum port. Since this force is in opposition to the force applied to the brake pedal by the driver it gives the driver a "feel" of the amount of brake applied. The proportion of reactive force applied to the valve plunger through the reaction disc is designed into the Master-Vac to ensure maximum power consistent with maintaining pedal feel. The reaction force is in direct proportion to the hydraulic pressure developed within the brake system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Vacuum Brake Booster: Symptom Related Diagnostic Procedures Decreasing Brake Pedal Travel If a decreasing brake pedal is encountered, the power brake unit may be binding internally. To test the power brake unit for this condition proceed as follows: 1. Place transmission shift lever in Neutral and START engine. 2. Increase engine speed to approximately 1500 rpm, close throttle and completely depress brake pedal. 3. Slowly release brake pedal and stop engine. 4. Remove vacuum check valve and hose from power brake unit. Observe brake pedal for backward movement. 5. If brake pedal moves backward, power brake unit has internal binding, and must be replaced. Dragging Brakes If brakes release slowly or incompletely (brakes drag), the power brake unit may be binding internally. To test for an internal bind condition, refer to Decreasing Brake Pedal Travel. Hard Brake Pedal A "hard" brake pedal could be caused by internal binding in the power unit or a failed vacuum check valve. Refer to Decreasing Brake Pedal Travel to test power brake unit for an internal bind. To check for a failed vacuum check valve, proceed as follows: 1. Start engine and increase engine speed to approximately 1500 rpm, then close throttle and stop engine. 2. Wait 90 seconds, then try brake action. 3. If brakes are not vacuum assisted for two or more applications, replace check valve. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4414 Vacuum Brake Booster: Component Tests and General Diagnostics General Service In order to properly service and repair available brake systems, a thorough understanding of the power assist systems is necessary. The vacuum assist diaphragm assembly multiplies the force exerted on the master cylinder piston in order to increase the hydraulic pressure delivered to the wheel cylinders or calipers while decreasing the effort necessary to obtain acceptable stopping performance. Vacuum assist units get their energy by opposing engine vacuum to atmospheric pressure. A piston, cylinder and flexible diaphragm utilize this energy to provide brake assistance. The diaphragm is balanced with engine vacuum until the brake pedal is depressed, allowing atmospheric pressure to unbalance the unit and apply force to the brake system. Brakes will operate even if the power unit fails. This means the conventional brake system and the power assist system are completely separate. Troubleshooting conventional and power assist systems are exactly the same until the power unit is reached. As with conventional hydraulic brakes, a spongy pedal still means air is trapped in the hydraulic system. Power brakes give higher line pressure, making leaks more critical. Checking Complaints Complaints about power brake operation should be handled as if two separate systems exist. Check for faults in the hydraulic system first. If it is satisfactory, start inspecting the power brake circuit. For a quick check of proper power unit operation, press the brake pedal firmly, then start the engine. The pedal should fall away slightly and less pressure should be needed to maintain the pedal in any position. Another check begins with installation of a suitable pressure gauge in the brake hydraulic system. Take a reading with the engine off and the power unit not operating. Maintaining the same pedal height, start the engine and take another reading. There should be a substantial pressure increase in the second reading. Pedal free travel and total travel are critical on cars equipped with power brakes. Pedal travel should be kept strictly to specifications. Take a manifold vacuum reading if the power unit isn't giving enough assistance. Remember, though, currently produced emission controlled engines, manifold vacuum readings may be less than 15 inches Hg at idle. If manifold vacuum is abnormally low, tune the engine and then try the power brakes again. Naturally, loose vacuum lines and clogged air intake filters will cut down brake efficiency. Most units have a check valve that retains some vacuum in the system when the engine is off. A vacuum gauge check of this valve will tell you when it is restricted or stuck open or closed. Failure of the brakes to release in most instances is caused by a tight or misaligned connection between the power unit and the brake linkage. If this connection is free, inspect for a broken piston, diaphragm or bellows and return spring. A simple check of the hydraulic system should be made before proceeding. Loosen the connection between the master cylinder and the brake booster. If the brakes release, the trouble is in the power unit; if the brakes still will not release, look for a restricted brake line or similar difficulties in the hydraulic circuit. A residual pressure check valve is usually included immediately under the brake line connection on hydraulic assist power brakes. This valve maintains a slight hydraulic pressure within the brake lines and wheel cylinders or caliper to give better pedal response. If it is sticking, the brakes may not release. Power brakes that have a hard pedal are usually suffering from a milder form of the same ills that cause complete power unit failure. Collapsed or leaking vacuum lines or insufficient manifold vacuum, as well as punctured diaphragms or bellows and leaky piston seals, all lead to weak power unit operation. A steady hiss when the brake is held down means a vacuum leak that will cause poor power unit operation. Do not immediately condemn the power unit if the brakes grab. First look for all the usual causes, such as greasy linings, scored rotors or drums. Then investigate the power unit. When the trouble has been traced to the power unit, check for a damaged reaction control. The reaction control is usually made up of a diaphragm, spring and valves that tends to resist pedal action. It is put in the system to give the pedal "feel." Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 4415 Vacuum Brake Booster: Adjustments PUSHROD ADJUSTMENT In some cases adjustment of the brake booster pushrod is necessary to ensure proper operation of the power brake system. A pushrod that is too long will cause the master cylinder piston to close off the compensating port, preventing hydraulic pressure from being released and resulting in brake drag. A pushrod that is too short will cause excessive brake pedal travel and cause groaning noises to come from the booster when the brakes are applied. A properly adjusted pushrod that remains assembled to the booster with which is was matched during production should not require service adjustment. However, if the booster, master cylinder or pushrod are serviced, the pushrod may require adjustment. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 4416 Vacuum Brake Booster: Service and Repair The content of this article reflects the changes called out by TSB 05-07-94. When repairing vehicles equipped with Antilock Brake Systems (ABS), the vacuum in the power booster must be pumped down before removing the master cylinder to avoid drawing in any contamination. This can be done simply by pumping the brake until a firm pedal is achieved, with ignition off. 1. On models with ABS systems, ensure ignition switch is Off and brake pedal has been pumped until firm. 2. On all models, disconnect wiring harness from brake fluid level sensor mounted on fluid reservoir. 3. Disconnect primary and secondary brake tubes from master cylinder housing and plug outlets on master cylinder. 4. On models with ABS systems, clean area where master cylinder attaches to power booster using a suitable cleaner. 5. On all models, remove mounting nuts and slide master cylinder forward out of booster. 6. On models equipped with ABS, the vacuum seal in the front of the power brake vacuum booster must be replaced. Remove vacuum seal in front of power brake vacuum booster by carefully inserting a small screwdriver between the master cylinder push rod and vacuum seal and prying the seal out of the booster. Do not attempt to pry seal out by inserting screwdriver between seal and booster. 7. On all models, disconnect vacuum hoses from power booster check valve. Do not remove check valve from power booster. 8. On models with ABS systems, remove Hydraulic Control Unit (HCU). 9. On all models, locate power booster input rod to brake pedal attachment under instrument panel. Position a suitable small screwdriver between center tang on input rod to brake pedal pin retaining clip. Rotate screwdriver to allow retaining clip center tang to pass over end of brake pedal pin. Discard retaining clip. 10. Remove power booster mounting nuts holding unit to dash panel. 11. Slide power booster forward until mounting studs clear dash, then tilt unit upward to remove. 12. Reverse procedure to install noting the following: a. On models with ABS, install new vacuum seal by lubricating master cylinder push rod using Mopar Silicone Dielectric Compound - NO Substitutes. Slide vacuum seal onto master cylinder push rod with notches on seal pointing toward and seated against master cylinder housing. b. On all models, install mounting nuts and torque to 21 ft. lbs. c. Connect brake tubes to master cylinder primary and secondary ports and torque tube nuts to 12 ft. lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Description and Operation ABS Main Relay: Description and Operation CIRCUIT OPERATION The system relay is used for the operation of the ABS system. Power for the relay is supplied on the B57 circuit from cavity 57 of the Controller Anti Lock Brake (CAB). Ground for the relay is on the Z1 circuit. This ground is spliced in with the pump motor and terminates at the left headlamp ground. When the system is operating normally power for the contact side of the relay is supplied from the CAB on the B57 circuit. It passes through the relay to the Z1 ground and terminates at the left headlamp ground. If a problem is detected in the system, the contact side of the relay switches from the Z1 to the F12 circuit. This causes the ABS warning lamp in the instrument cluster to illuminate. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Description and Operation Brake Fluid Pump Relay: Description and Operation CIRCUIT OPERATION The ABS pump motor relay controls when the pump motor runs. Power for the coil side of the relay is supplied from cavity 47 of the Controller Anti Lock Brake (CAB) on the B47 circuit. This circuit also supplies voltage for the contact side of the system relay The ground side of the coil is controlled by the B116 circuit. Circuit B116 connects to cavity 16 of the CAB connector. Circuit B120 from cavity 20 of the CAB connector powers the ABS pump motor. This circuit is also used as an input to the CAB for pump motor monitoring. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation Electronic Brake Control Module: Description and Operation Fig 1 Controller Anti-Lock Brake System (CAB) Fig 2 Controller Anti-Lock System (CAB) The Controller, Antilock Brake (CAB) located under the lefthand side of the instrument panel is a microprocessor device which monitors wheel speed and controls Antilock Brake System (ABS). The CAB monitors the speed of each wheel through the signals generated at the wheel speed sensors to determine if any wheel is beginning to lock. If any wheel lock is detected, the CAB commands the Hydraulic Control Unit (HCU) to modulate pressure to some or all of the hydraulic circuits. The CAB constantly monitors the ABS system for proper operation. If the CAB detects a fault, it will turn on the ABS warning lamp and disable the ABS braking system. The CAB contains a self-diagnostic program which will store system faults in a diagnostic program memory. There are multiple fault messages which may be stored in the CAB memory and can be displayed with a DRB or equivalent scan tool. These faults will remain in the CAB memory even after the ignition has been turned off. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Page 4427 Electronic Brake Control Module: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect wiring harness 60-way connector from CAB. 3. Remove two CAB bracket to driver's side cowl mounting nuts. 4. Remove CAB from vehicle. 5. Reverse procedure to install, torque 60-way connector retaining bolt to 38 inch lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Description and Operation Braking Sensor/Switch: Description and Operation CIRCUIT OPERATION Circuit L50 is an input to the Controller Anti Lock Brake (CAB). The L50 connects to cavity 13 of the CAB connector. Circuit L50 is spliced in with the stop lamps and is used to provide the CAB with information on when the brakes are being applied. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Testing and Inspection Parking Brake Warning Switch: Testing and Inspection In the START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) to circuit A41. A 30 Amp fuse protects circuits A1 and A41. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4439 39 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4440 43 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4441 45 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4442 47 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4443 51 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4444 55 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4445 57 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4446 59 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4447 63 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4448 67 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4449 69 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4450 71 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4451 173 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4452 177 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4453 179 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4454 181 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4455 187 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4456 191 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4457 193 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4458 195 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4459 201 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4460 205 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4461 207 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4462 209 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 4463 256 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 4464 Wheel Speed Sensor: Description and Operation OPERATION One wheel speed sensor (WSS) is located at each wheel and sends an AC signal to the Controller, Antilock Brake (CAB). The voltage is generated by magnetic induction when a tooth sensor ring passes by a stationary magnetic sensor. The CAB then converts the AC signal into digital signals for each wheel. The four wheel speed sensors are serviced individually. CIRCUIT OPERATION There are four wheel speed sensors, one at each wheel. The sensors use a tone wheel to determine wheel speed. Input to the Controller Anti Lock Brake (CAB) is done on the following circuits. All of these circuits are a twisted pair. B8 and B9 for the left front wheel (cavity 8 and cavity 9). B6 and B7 for the right front wheel (cavity 6 and cavity 7). B3 and B4 for the left rear wheel (cavity 3 and cavity 4). B1 and B2 for the right rear wheel (cavity 1 and cavity 2). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 4465 Wheel Speed Sensor: Service and Repair Inspect tone wheel for missing or broken teeth, ensure tone wheel has not made contact with wheel speed sensor. Replace tone wheel if runout exceeds 0.010 inch. FRONT 1. Raise and support vehicle, then remove tire and wheel assembly. 2. Remove grommet retaining clip attaching screw, then pull sensor assembly grommet from fender shield. 3. Unplug speed sensor connector from vehicle wiring harness connector, then remove speed sensor cable routing bracket from front strut assembly. 4. Remove screw attaching speed sensor head to steering knuckle, then sensor from steering knuckle. Do not use pliers on sensor head, use a hammer and punch to tap edge of sensor ear, rocking sensor side to side until free. 5. Reverse procedure to install noting the following: a. Coat sensor head with high temperature multi-purpose E.P grease. b. Torque speed sensor head to 60 inch lbs. c. In two steps, torque wheel lug nuts to 95 ft. lbs. REAR 1. Disconnect battery ground cable. 2. Raise and support vehicle. 3. Remove rear tire and wheel assembly. 4. Remove clip attaching speed sensor cable connector to vehicle body, then disconnect speed sensor cable connector from vehicle wiring harness. 5. Remove speed sensor cable routing bracket from rear brake flex hose mounting bracket. 6. Remove speed sensor cable from routing clips on rear brake flex hose and chassis brake tube. 7. Remove speed sensor attaching bolt from drum brake support or disc brake adapter. 8. Remove speed sensor cable routing bracket attaching bolt from rear strut assembly. 9. Remove sensor head from support plate or adapter. Do not use pliers on sensor head, use a hammer and punch to tap edge of sensor ear, rocking sensor side to side until free. 10. Reverse procedure to install, torque speed sensor attaching bolt to 60 inch lbs. and wheel lug nuts to 80-110 ft. lbs.. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Battery Temp Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4471 Battery Temp Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 4472 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation > General Description Battery Temperature Sensor: Description and Operation General Description CIRCUIT OPERATION From circuit G31 the battery temperature sensor draws voltage from the Powertrain Control Module (PCM). The sensor is a variable resistor. As battery temperature changes, the resistance in the sensor changes causing a change in current draw. Circuit G31 connects to cavity 52 of the PCM connector. The PCM provides ground for the battery temperature sensor signal (circuit G31) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation > General Description > Page 4475 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor Operation Sensor External to the PCM Name of Code: Battery Temp Sensor (BTS) Voltage Either Too High or Too Low When Monitored: With the ignition key on. Set Condition: The PCM senses the voltage from the BTS to be either below 0.5 volts or above 4.9 volts for 3 seconds. Theory of Operation: The battery temp sensor voltage is used by the PCM to determine what the charging system goal should be. The PCM uses that goal to determine the charging output level. The battery temp sensor is external to the PCM. Possible Causes: - Battery temp sensor failure - Open circuit in battery temp sensor signal circuit - Short circuit in battery temp sensor signal circuit - PCM failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Battery Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Service and Repair Clutch Switch: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect electrical connector from switch. 3. Depress tabs on switch and push through mounting bracket. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation Fig.16 Ignition Lock Cylinder Detents The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detents: Accessory - Off (lock) - Unlock - On/Run - Start Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4485 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Detentes The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detentes: Accessory - Off (lock) - Unlock - On/Run - Start REMOVAL 1. Disconnect negative cable from battery. 2. Place key cylinder in RUN position. - Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. - Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. - To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. - Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Connect negative cable to battery Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Transmission Control Solenoid Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 4489 Park Neutral Position Switch Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 4490 Neutral Safety Switch: Description and Operation CIRCUIT OPERATION When CLOSED, the park/neutral position switch provides a ground path on circuit T41 for the coil side of the engine starter motor relay The case grounded switch provides ground for circuit T41. Circuit A41 from the ignition switch provides battery voltage to the coil side of the relay. Circuit T41 splices to cavity 76 of the Powertrain Control Module (PCM). The park/neutral position switch provides an input to the PCM. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 4491 Neutral Safety Switch: Testing and Inspection In the START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) to circuit A41. A 30 Amp fuse protects circuits A1 and A41. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution (Part 1 Of 2) Fig. 15 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 4496 Starter Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Battery Temp Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4501 Battery Temp Sensor Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 4502 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Description and Operation > General Description Battery Temperature Sensor: Description and Operation General Description CIRCUIT OPERATION From circuit G31 the battery temperature sensor draws voltage from the Powertrain Control Module (PCM). The sensor is a variable resistor. As battery temperature changes, the resistance in the sensor changes causing a change in current draw. Circuit G31 connects to cavity 52 of the PCM connector. The PCM provides ground for the battery temperature sensor signal (circuit G31) through circuit K4. Circuit K4 connects to cavity 43 of the PCM connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Description and Operation > General Description > Page 4505 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor Operation Sensor External to the PCM Name of Code: Battery Temp Sensor (BTS) Voltage Either Too High or Too Low When Monitored: With the ignition key on. Set Condition: The PCM senses the voltage from the BTS to be either below 0.5 volts or above 4.9 volts for 3 seconds. Theory of Operation: The battery temp sensor voltage is used by the PCM to determine what the charging system goal should be. The PCM uses that goal to determine the charging output level. The battery temp sensor is external to the PCM. Possible Causes: - Battery temp sensor failure - Open circuit in battery temp sensor signal circuit - Short circuit in battery temp sensor signal circuit - PCM failure - Connector terminals - Connector wires Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Testing and Inspection > Helpful Information Battery Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Crankshaft position sensor - Engine coolant temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams Alternator Field Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Description and Operation > Alternator Operation Alternator: Description and Operation Alternator Operation The main components of the alternator are the rotor, stator, rectifier, end shields and drive pulley. Direct current is available at the output "B+" terminal. Alternator output is controlled by voltage regulator circuitry contained within the power and logic modules of the Engine Controller. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Description and Operation > Alternator Operation > Page 4514 Alternator: Description and Operation Diode Rectifiers DIODE RECTIFIERS Six or more silicon diode rectifiers are used and act as electrical one-way valves. One half of the diodes have ground polarity and are pressed or screwed into a heat sink which is grounded. The other diodes (ungrounded) are pressed or screwed into and insulated from the end head. These diodes are connected to the alternator output terminal. Since the diodes have a high resistance to the flow of current in one direction and a low resistance in the opposite direction, they may be connected in a manner which allows current to flow from the alternator to the battery in the low resistance direction. The high resistance in the opposite direction prevents the flow of current from the battery to the alternator. Because of this feature no circuit breaker is required between the alternator and battery. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Description and Operation > Page 4515 Alternator: Service and Repair 1. Disconnect battery ground cable. 2. Loosen alternator adjustment nut. 3. Turn front wheels fully to right, then raise and support vehicle. 4. Remove lower splash shield. 5. Disconnect alternator wiring. 6. Loosen alternator pivot bolt. 7. Remove alternator drive belt. 8. Remove three bolts from pivot bracket. 9. Remove pivot nut from T-bolt while supporting alternator. 10. Lower alternator and remove through wheelwell. 11. Reverse procedure to install, noting the following: a. Torque alternator mounting bolts to 40 ft.-lbs. b. Torque alternator feed terminal nut to 75 in.-lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Service and Repair Clutch Switch: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect electrical connector from switch. 3. Depress tabs on switch and push through mounting bracket. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Description and Operation Ignition Lock: Description and Operation All vehicles equipped with automatic transaxles have an interlock system. The system prevents shifting the vehicle out of Park unless the ignition lock cylinder is in the Off, Run or Start position. In addition, the operator cannot rotate the key to the lock position unless the shifter is in the park position. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Description and Operation > Page 4523 Ignition Lock: Service and Repair Ignition Switch Replacement Fig.40 Ignition Switch - Viewed From Below Column The ignition switch attaches to the lock cylinder housing on the end opposite the lock cylinder. For ignition switch terminal and circuit identification, refer to Diagrams/Electrical. REMOVAL 1. Disconnect negative cable from battery. Fig.41 Steering Column Shrouds 2. Place key cylinder in RUN position. Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder. 3. Remove upper and lower shrouds from steering column. 4. Disconnect electrical connectors from ignition switch. Fig.42 Ignition Switch Mounting Screw Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Description and Operation > Page 4524 5. Remove ignition switch mounting screw with a #10 Torx' bit. Fig.43 Removing Ignition Switch 6. Depress retaining tabs and pull ignition switch from steering column. INSTALLATION 1. Ensure the ignition switch is in the RUN position and the actuator shaft in the lock housing is in the RUN position. Fig.44 Ignition Switch Installation 2. Carefully install the ignition switch. The switch will snap over the retaining tabs. Install mounting screw. 3. Install electrical connectors to ignition switch. 4. Install upper and lower shrouds. 5. Install key cylinder (cylinder retaining tab will depress only in the RUN position). 6. Connect negative cable to battery. 7. Check for proper operation of ignition switch and key-in warning switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation Fig.16 Ignition Lock Cylinder Detents The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detents: Accessory - Off (lock) - Unlock - On/Run - Start Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4529 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Detentes The lock cylinder is inserted in the end of the housing opposite the ignition switch. The ignition key rotates the cylinder to 5 different detentes: Accessory - Off (lock) - Unlock - On/Run - Start REMOVAL 1. Disconnect negative cable from battery. 2. Place key cylinder in RUN position. - Through the hole in the lower shroud, depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. - Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. - To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. - Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Connect negative cable to battery Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Transmission Control Solenoid Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 4533 Park Neutral Position Switch Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 4534 Neutral Safety Switch: Description and Operation CIRCUIT OPERATION When CLOSED, the park/neutral position switch provides a ground path on circuit T41 for the coil side of the engine starter motor relay The case grounded switch provides ground for circuit T41. Circuit A41 from the ignition switch provides battery voltage to the coil side of the relay. Circuit T41 splices to cavity 76 of the Powertrain Control Module (PCM). The park/neutral position switch provides an input to the PCM. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 4535 Neutral Safety Switch: Testing and Inspection In the START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) to circuit A41. A 30 Amp fuse protects circuits A1 and A41. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications Starter Motor: Specifications Free Speed Test Power Rating, Kw ................................................................................................................................ ....................................................................... 0.95 Max. Amps ........................................................... ........................................................................................................................................................... -- Volts ................................................................................................................................................. ............................................................................... -Minimum RPM ..................................................................................................................................... ............................................................................... -- Cranking Amp Draw Test [01] .......................... ....................................................................................................................................................... 150-180 [01] -- With engine @ operating temperature. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > With A/C Starter Motor: Service and Repair With A/C Fig. 6 Remove And Install Battery Cables STARTER REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle. 3. Using a floor jack or jack stand, support the engine and transmission assembly so they will not rotate. Fig. 12 Front Engine Mount Bolt Removal 4. Remove the front engine mount through bolt from the insulator and front crossmember mounting bracket. 5. Lower engine to rotate it forward to allow easy removal of starter motor. 6. For easier servicing, do not remove the wiring from starter at this time. Fig. 13 Starter Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > With A/C > Page 4541 7. Remove two bolts attaching starter to transmission housing. 8. Remove starter/starter solenoid assembly from transmission housing. Position the starter to gain access to the wiring connectors. Fig. 14 Wire Connection 7. Remove the battery positive cable nut and remove the battery positive and generator output wire from the starter. 8. Disconnect push-on solenoid connector. 9. Position the starter vertically such that the pinion end faces downward. 10. Remove the starter through the bottom of the vehicle. Move a side A/C plumbing as necessary. INSTALLATION 1. Clean corrosion/dirt from the cable and wire terminals before installing wiring to the solenoid. 2. Connect the battery positive and generator output wire to the starter solenoid post. CAUTION: It is critical that the generator output terminal be connected to the battery positive terminal of the starter solenoid, for proper operation of the charging and cranking systems. 3. Connect the push-on solenoid connector. 4. Set starter face into transmission housing. Support starter in pilot and start the top bolt. 5. Attach ground cable to lower mounting bolt and start bolt. 6. Tighten both mounting bolts to 30 Nm (40 ft lb) torque and assuring proper starter alignment. 7. Using a floor jack or jack stand, raise the engine and transmission assembly to the original position. 8. Install the front engine mount through bolt through the insulator and front crossmember mounting bracket. 9. Tighten bolt to 54 Nm (40 ft lb) torque. 10. Lower vehicle and connect battery cables. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > With A/C > Page 4542 Starter Motor: Service and Repair Without A/C Fig. 6 Remove And Install Battery Cables STARTER REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle. 3. For easier servicing, do not remove the wiring from starter at this time. Fig. 13 Starter Removal 4. Remove two bolts attaching starter to transmission housing. 5. Remove starter/starter solenoid assembly from transmission housing. Position the starter to gain access to the wiring connectors. Fig. 14 Wire Connection Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > With A/C > Page 4543 7. Remove the battery positive cable nut and remove the battery positive and generator output wire from the starter. 8. Disconnect push-on solenoid connector. 9. Position the starter vertically such that the pinion end faces downward. 10. Remove the starter through the bottom of the vehicle. Move a side A/C plumbing as necessary. INSTALLATION 1. Clean corrosion/dirt from the cable and wire terminals before installing wiring to the solenoid. 2. Connect the battery positive and generator output wire to the starter solenoid post. CAUTION: It is critical that the generator output terminal be connected to the battery positive terminal of the starter solenoid, for proper operation of the charging and cranking systems. 3. Connect the push-on solenoid connector. 4. Set starter face into transmission housing. Support starter in pilot and start the top bolt. 5. Attach ground cable to lower mounting bolt and start bolt. 6. Tighten both mounting bolts to 30 Nm (40 ft lb) torque and assuring proper starter alignment. 7. Lower vehicle and connect battery cables. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution (Part 1 Of 2) Fig. 15 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 4547 Starter Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations Power Distribution Center: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Page 4552 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions Power Distribution Center: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4555 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4556 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4557 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4558 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4559 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4560 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4561 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4562 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4563 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4564 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4565 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4566 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4567 Power Distribution Center: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4568 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4569 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4570 Power Distribution Center: Connector Views Power Distribution (Part 1 Of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4571 Power Distribution (Part 2 Of 2) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4572 Power Distribution Center: Electrical Diagrams Power Distribution Power Distribution (Part 1 Of 4) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4573 Power Distribution (Part 2 Of 4) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4574 Power Distribution (Part 3 Of 4) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4575 Power Distribution (Part 4 Of 4) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Ground Distribution Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4576 Ground Distribution (Part 1 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4577 Ground Distribution (Part 2 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4578 Ground Distribution (Part 3 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4579 Ground Distribution (Part 4 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4580 Ground Distribution (Part 5 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4581 Ground Distribution (Part 6 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4582 Ground Distribution (Part 7 Of 7) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations Fuse: Locations The fuse panel is located behind the left side of the instrument panel, left of the steering column. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4588 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4589 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4590 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4591 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4592 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4593 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4594 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4595 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4596 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4597 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4598 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4599 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4600 Fuse: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4601 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4602 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4603 Fuse: Connector Views Fuse/Fuse Block (Part 1 Of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4604 Fuse/Fuse Block (Part 2 Of 2) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4605 Fuse: Electrical Diagrams Fuse/Fuse Block (Part 1 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4606 Fuse/Fuse Block (Part 2 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4607 Fuse/Fuse Block (Part 3 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4608 Fuse/Fuse Block (Part 4 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4609 Fuse/Fuse Block (Part 5 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4610 Fuse/Fuse Block (Part 6 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4611 Fuse/Fuse Block (Part 7 Of 7) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations The fuse panel is located behind the left side of the instrument panel, left of the steering column. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4617 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4618 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4619 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4620 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4621 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4622 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4623 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4624 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4625 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4626 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4627 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4628 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4629 Fuse Block: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4630 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4631 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4632 Fuse Block: Connector Views Fuse/Fuse Block (Part 1 Of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4633 Fuse/Fuse Block (Part 2 Of 2) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4634 Fuse Block: Electrical Diagrams Fuse/Fuse Block (Part 1 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4635 Fuse/Fuse Block (Part 2 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4636 Fuse/Fuse Block (Part 3 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4637 Fuse/Fuse Block (Part 4 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4638 Fuse/Fuse Block (Part 5 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4639 Fuse/Fuse Block (Part 6 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4640 Fuse/Fuse Block (Part 7 Of 7) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4645 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4649 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations Power Distribution Center: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Locations > Page 4654 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions Power Distribution Center: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4657 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4658 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4659 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4660 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4661 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4662 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4663 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4664 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4665 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4666 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4667 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4668 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4669 Power Distribution Center: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4670 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4671 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4672 Power Distribution Center: Connector Views Power Distribution (Part 1 Of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4673 Power Distribution (Part 2 Of 2) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4674 Power Distribution Center: Electrical Diagrams Power Distribution Power Distribution (Part 1 Of 4) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4675 Power Distribution (Part 2 Of 4) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4676 Power Distribution (Part 3 Of 4) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4677 Power Distribution (Part 4 Of 4) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Ground Distribution Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4678 Ground Distribution (Part 1 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4679 Ground Distribution (Part 2 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4680 Ground Distribution (Part 3 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4681 Ground Distribution (Part 4 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4682 Ground Distribution (Part 5 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4683 Ground Distribution (Part 6 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 4684 Ground Distribution (Part 7 Of 7) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations Fuse: Locations The fuse panel is located behind the left side of the instrument panel, left of the steering column. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4690 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4691 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4692 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4693 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4694 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4695 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4696 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4697 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4698 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4699 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4700 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4701 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4702 Fuse: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4703 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4704 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4705 Fuse: Connector Views Fuse/Fuse Block (Part 1 Of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4706 Fuse/Fuse Block (Part 2 Of 2) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4707 Fuse: Electrical Diagrams Fuse/Fuse Block (Part 1 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4708 Fuse/Fuse Block (Part 2 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4709 Fuse/Fuse Block (Part 3 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4710 Fuse/Fuse Block (Part 4 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4711 Fuse/Fuse Block (Part 5 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4712 Fuse/Fuse Block (Part 6 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4713 Fuse/Fuse Block (Part 7 Of 7) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations The fuse panel is located behind the left side of the instrument panel, left of the steering column. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4719 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4720 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4721 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4722 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4723 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4724 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4725 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4726 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4727 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4728 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4729 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4730 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4731 Fuse Block: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4732 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4733 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4734 Fuse Block: Connector Views Fuse/Fuse Block (Part 1 Of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4735 Fuse/Fuse Block (Part 2 Of 2) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4736 Fuse Block: Electrical Diagrams Fuse/Fuse Block (Part 1 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4737 Fuse/Fuse Block (Part 2 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4738 Fuse/Fuse Block (Part 3 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4739 Fuse/Fuse Block (Part 4 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4740 Fuse/Fuse Block (Part 5 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4741 Fuse/Fuse Block (Part 6 Of 7) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4742 Fuse/Fuse Block (Part 7 Of 7) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4747 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4751 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration Alignment: Customer Interest Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 4761 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 4762 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration Alignment: All Technical Service Bulletins Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 4768 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 4769 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment Alignment: All Technical Service Bulletins Alignment & Suspension - Specifications & Adjustment NO: 02-04-97 GROUP: Suspension DATE: May 16, 1997 SUBJECT: Front End Alignment Torque Specifications & Shock Adjustment Procedures On Competition Package MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH THE COMPETITION PACKAGE SALES CODE (ACR) SUSPENSION SALES CODE (SDK). DISCUSSION: The alignment on ACR equipped vehicles must be set to the preferred specifications provided in the 1997 Neon Service Manual (Publication Number 81-270-7025) page 2-7. After each final setting the nuts should then be torqued to 75 ft.lbs plus an additional 90 degree turn. It is important that the proper torque be used to maintain the proper alignment. If the alignment is outside of specifications, rapid and excessive tire wear will result. Starting in 1997, Neon competition package (ACR) vehicles come equipped with adjustable strut dampers on all four wheels. The struts are finely tuned to the ride and handling profile of the entire suspension system. If the customer wishes to change the dampening force for special conditions the dampening characteristics of the strut dampers are adjustable on the ACR equipped vehicles. The knob for adjusting the strut can be found in a packet located in the glove compartment. The adjustment procedures are as follows: 1. The top end of the adjusting rod has flats over which the adjusting knob will fit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment > Page 4774 2. Install the knob over the top end of the front or rear damper and lock it into position by turning counterclockwise slowly until the knob engages, (Illustration). 3. Turn the adjusting knob clockwise, if resistance is felt do not use force, as the damper is in an unadjusted position. Reverse the adjustment slightly and try again. When the damper is in the full clockwise position, this is the minimum (City Ride) position. 4. To adjust the dampening force, the adjusting knobs has to be turned in the direction of the arrow for increased dampening and the opposite direction for decreased dampening. NOTE: BOTH THE LEFT AND RIGHT STRUT DAMPERS MUST BE ADJUSTED IDENTICALLY. FAILURE TO DO SO COULD PRODUCE UNSTABLE HANDLING AND UNEVEN TIRE TREAD WEAR. 5. The following is a description of the various settings and the adjustment procedure. A. City Ride - To enjoy the most comfortable city ride, the struts should be left in the "minimum" position as they are set from the assembly plant. To set to minimum the knob should be turned completely clockwise. B. Cross Country - The cross country setting will give the car a firmer handling characteristic, but yet will still be very comfortable to drive. To set, turn the adjusting knob 1/2 turn counter clockwise from the "minimum" position. C. G.T./Aggressive Driving - This setting equates the car's handling to a cross-country grand turismo car, offering increased cornering ability, improved road feel and precise directional stability at higher speeds. To set turn the adjusting knob 1 turn counter clockwise from the "minimum" position. 6. Remove the adjusting knob before closing the hood or trunk. The vehicle should not be driven with the adjusting knob in place. NOTE: DURING INSPECTION/SERVICING A THIN FILM OF OIL AND DUST COLLECTION MAY BE NOTICED ON THE OUTSIDE OF THE STRUT TUBE. THIS IS A NORMAL CONDITION WHICH OCCURS DURING THE DAMPER INTERNAL SEAL "BREAK-IN" PERIOD AND DOES NOT AFFECT THE PERFORMANCE OF THE STRUT AND DOES NOT INDICATE THE NEED FOR STRUT REPLACEMENT. STRUT REPLACEMENT SHOULD ONLY OCCUR IF THE STRUT LEAKAGE IS SUFFICIENT TO COVER THE ENTIRE STRUT DAMPER TUBE AND HAS "DRIPPED" ONTO THE LOWER CONTROL ARM OR ONTO THE PAVEMENT DURING OVERNIGHT PARKING. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 26-12-96G > Dec > 96 > Steering/Suspension - Alignment Specifications Revisions Alignment: All Technical Service Bulletins Steering/Suspension - Alignment Specifications Revisions NUMBER: 26-12-96G GROUP: Miscellaneous DATE: December, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1996 Neon - Publication Number 81-270-6025 DESCRIPTION OF CHANGES Revision the front end alignment specifications Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 26-12-96G > Dec > 96 > Steering/Suspension - Alignment Specifications Revisions > Page 4779 2-7 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment Alignment: All Technical Service Bulletins Alignment & Suspension - Specifications & Adjustment NO: 02-04-97 GROUP: Suspension DATE: May 16, 1997 SUBJECT: Front End Alignment Torque Specifications & Shock Adjustment Procedures On Competition Package MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH THE COMPETITION PACKAGE SALES CODE (ACR) SUSPENSION SALES CODE (SDK). DISCUSSION: The alignment on ACR equipped vehicles must be set to the preferred specifications provided in the 1997 Neon Service Manual (Publication Number 81-270-7025) page 2-7. After each final setting the nuts should then be torqued to 75 ft.lbs plus an additional 90 degree turn. It is important that the proper torque be used to maintain the proper alignment. If the alignment is outside of specifications, rapid and excessive tire wear will result. Starting in 1997, Neon competition package (ACR) vehicles come equipped with adjustable strut dampers on all four wheels. The struts are finely tuned to the ride and handling profile of the entire suspension system. If the customer wishes to change the dampening force for special conditions the dampening characteristics of the strut dampers are adjustable on the ACR equipped vehicles. The knob for adjusting the strut can be found in a packet located in the glove compartment. The adjustment procedures are as follows: 1. The top end of the adjusting rod has flats over which the adjusting knob will fit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 02-04-97 > May > 97 > Alignment & Suspension - Specifications & Adjustment > Page 4785 2. Install the knob over the top end of the front or rear damper and lock it into position by turning counterclockwise slowly until the knob engages, (Illustration). 3. Turn the adjusting knob clockwise, if resistance is felt do not use force, as the damper is in an unadjusted position. Reverse the adjustment slightly and try again. When the damper is in the full clockwise position, this is the minimum (City Ride) position. 4. To adjust the dampening force, the adjusting knobs has to be turned in the direction of the arrow for increased dampening and the opposite direction for decreased dampening. NOTE: BOTH THE LEFT AND RIGHT STRUT DAMPERS MUST BE ADJUSTED IDENTICALLY. FAILURE TO DO SO COULD PRODUCE UNSTABLE HANDLING AND UNEVEN TIRE TREAD WEAR. 5. The following is a description of the various settings and the adjustment procedure. A. City Ride - To enjoy the most comfortable city ride, the struts should be left in the "minimum" position as they are set from the assembly plant. To set to minimum the knob should be turned completely clockwise. B. Cross Country - The cross country setting will give the car a firmer handling characteristic, but yet will still be very comfortable to drive. To set, turn the adjusting knob 1/2 turn counter clockwise from the "minimum" position. C. G.T./Aggressive Driving - This setting equates the car's handling to a cross-country grand turismo car, offering increased cornering ability, improved road feel and precise directional stability at higher speeds. To set turn the adjusting knob 1 turn counter clockwise from the "minimum" position. 6. Remove the adjusting knob before closing the hood or trunk. The vehicle should not be driven with the adjusting knob in place. NOTE: DURING INSPECTION/SERVICING A THIN FILM OF OIL AND DUST COLLECTION MAY BE NOTICED ON THE OUTSIDE OF THE STRUT TUBE. THIS IS A NORMAL CONDITION WHICH OCCURS DURING THE DAMPER INTERNAL SEAL "BREAK-IN" PERIOD AND DOES NOT AFFECT THE PERFORMANCE OF THE STRUT AND DOES NOT INDICATE THE NEED FOR STRUT REPLACEMENT. STRUT REPLACEMENT SHOULD ONLY OCCUR IF THE STRUT LEAKAGE IS SUFFICIENT TO COVER THE ENTIRE STRUT DAMPER TUBE AND HAS "DRIPPED" ONTO THE LOWER CONTROL ARM OR ONTO THE PAVEMENT DURING OVERNIGHT PARKING. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 26-12-96G > Dec > 96 > Steering/Suspension - Alignment Specifications Revisions Alignment: All Technical Service Bulletins Steering/Suspension - Alignment Specifications Revisions NUMBER: 26-12-96G GROUP: Miscellaneous DATE: December, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1996 Neon - Publication Number 81-270-6025 DESCRIPTION OF CHANGES Revision the front end alignment specifications Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 26-12-96G > Dec > 96 > Steering/Suspension - Alignment Specifications Revisions > Page 4790 2-7 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4791 Alignment: By Symptom Technical Service Bulletin # 02-09-99 Date: 990702 Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4792 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4793 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Technical Service Bulletin # 02-09-99 Date: 990702 Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4794 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4795 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 4796 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 4797 Alignment: Specifications The content of this article reflects changes called for in TSB 26-12-96. NOTE: All alignment specifications are taken at curb height. FRONT: Camber: Acceptable Range ................................................................................................................ ........................................................................ -0.4° to +0.4° Preferred Setting .................................. .............................................................................................................................................................. .......... 0.0° S/C ACR only [3] ............................................................................................................... .......................................................................... -2.4° to +0.4° Total Toe [1]: Acceptable Range ......................................................................................................... ........................................................................ 0.3° in to 0.1° out Preferred Setting ............................ .............................................................................................................................................................. ............ 0.1° in S/C ACR only [3] ......................................................................................................... ................................................................... 0.30° In to 0.70° Out Caster*: Acceptable Range ................................................................................................................. ....................................................................... +1.8° to +3.8° Preferred Setting .................................. .............................................................................................................................................................. ........ +2.8° * Side To Side Caster: Not To Exceed ................................................................................................ ................................................................................................. 1.0° or less REAR: Camber: Acceptable Range ................................................................................................................ .................................................................... -0.75° to +0.25° Preferred Setting .................................. .............................................................................................................................................................. ....... -0.25° S/C ACR only [3] ............................................................................................................... ...................................................................... -1.00° to +0.25° Total Toe [1] [2]: Acceptable Range .................................................................................................... .............................................................................. 0.3° in to 0.1°out Preferred Setting ....................... .............................................................................................................................................................. ................. 0.1° in S/C ACR only [3] .................................................................................................... ........................................................................ 0.30° In to 0.50° Out Thrust Angle ........................................................................................................................................ .................................................... -0.10° to +0.10° [1]: Total toe is the arithmetic sum of the left and right wheel toe settings. Positive is toe-in, negative is toe-out. Total toe must be equally split between each front wheel to ensure the steering wheel is centered after setting toe. Left and right toe must be equal to within 0.02 degrees. [2]: Toe-out when backed on to the alignment rack is toe in when driving. [3]: The alignment specifications shown, are only for vehicles which are equipped with the ACR (Competition Package) sales code. This specification is listed to show the adjustable range for the Camber and Toe on the front and rear suspension of a vehicle with the Competition Package. These alignment specifications are only to be used at the request of the vehicle owner and only when the vehicle is going to be used in a competition event. The alignment is to be set back to the preferred setting before the vehicle is returned to normal operation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Alignment Alignment: Service and Repair Front Alignment Adjustment Camber & Toe Alignment Caster and camber settings are determined by the location of vehicle's suspension components. No adjustment of caster and camber is possible after vehicle is built or when servicing suspension components. Caster and camber are not normally considered an adjustable specification when performing an alignment on this vehicle. CASTER If caster is not within specifications, check for damaged suspension components or body damage causing component locations to change. NOTE: No adjustment is possible for caster. CAMBER 1. Correctly position vehicle on alignment rack and install all required equipment, per alignment equipment specifications. 2. Center steering wheel and lock in place using steering wheel clamp. 3. Jounce vehicle, then read front alignment settings and compare to specifications. 4. If camber readings obtained are not within specifications, a Mopar Service Kit will be required. 5. Raise and support vehicle, then remove original upper bolt attaching front strut clevis bracket to steering knuckle. 6. Loosen lower bolt attaching strut clevis bracket to steering knuckle only enough to allow knuckle to move in clevis bracket. 7. Install bolt from service kit into upper strut clevis bracket to steering knuckle mounting hole. 8. Install nut provided by service kit on replacement bolt. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Alignment > Page 4800 9. Tighten upper bolt and nut from service kit until snug, but still allowing movement between strut clevis bracket and knuckle. 10. Remove original lower bolt and install bolt from service kit into lower strut clevis bracket hole. Install nut and tighten until snug. 11. Lower vehicle until full weight is supported by suspension, then jounce front and rear of vehicle an equal number of times. 12. Adjust camber to preferred setting by pushing or pulling top of tire. 13. Tighten upper and lower strut clevis bracket bolts. 14. Jounce vehicle an equal number of times and verify rear camber setting. When vehicle is at correct setting, torque both front strut clevis brackets to 40 ft. lbs. plus an additional 1/4 turn. TOE Rear wheel toe must be set prior to setting front wheel toe. Proceed as follows: 1. Center steering wheel and lock in place using a steering wheel clamp. Rear Lateral Link Toe Setting 2. Loosen nuts on attaching bolts for left and right lateral links to rear crossmember. Rear Wheel Toe Adjustment Cams 3. Rotate lateral link adjustment cams, until preferred rear toe specification is obtained. 4. While holding toe adjustment cams from turning, tighten right and left lateral links to rear crossmember attaching bolt nuts. This will securely hold adjustment cams in position. 5. Hold lateral link attaching bolt and adjustment cam from turning and torque lateral link attaching bolt to 70 ft.-lbs. 6. Loosen front inner tie rod end jam nuts, then grasp inner tie rods at serration. 7. Rotate inner tie rods of steering gear and set front toe specifications. 8. Torque tie rod lock nuts to 45 ft.-lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Alignment > Page 4801 Preliminary Inspection - Ensure vehicle has a full tank of gas when wheel alignment specifications are checked or adjusted. One full tank of gas is approximately 75 lbs. - If tank is not full, this change in weight will affect curb height of vehicle and alignment specifications. - Check and adjust tire pressure. Ensure all tires are the same size. - Inspect all suspension components for looseness or damage. Components showing signs of wear or damage should be replaced before alignment. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Alignment > Page 4802 Alignment: Service and Repair Rear Alignment Camber & Toe Alignment Caster and camber settings are determined by the location of vehicle's suspension components. No adjustment of caster and camber is possible after vehicle is built or when servicing suspension components. Caster and camber are not normally considered an adjustable specification when performing an alignment on this vehicle. CASTER If caster is not within specifications, check for damaged suspension components or body damage causing component locations to change. - No adjustment is possible for caster. CAMBER 1. Correctly position vehicle on alignment rack and install all required equipment, per alignment equipment specifications. 2. Jounce vehicle and read rear alignment settings and compare to specifications. 3. If camber readings obtained are not within specifications, a Mopar Service Kit will be required. 4. Raise and support vehicle, then remove original upper bolt attaching rear strut clevis bracket to rear knuckle. 5. Loosen lower bolt attaching strut clevis bracket to rear knuckle only enough to allow knuckle to move in clevis bracket. 6. Install bolt from service kit into upper strut clevis bracket to rear knuckle mounting hole. 7. Install nut provided by service kit on replacement bolt. 8. Tighten upper bolt and nut from service kit until snug, but still allowing movement between strut clevis bracket and knuckle. 9. Remove original lower bolt and install bolt from service kit into lower strut clevis bracket hole. Install nut and tighten until snug. 10. Lower vehicle until full weight is supported by suspension, then jounce front and rear of vehicle an equal number of times. 11. Adjust camber to preferred setting by pushing or pulling top of tire. 12. Tighten upper and lower strut clevis bracket bolts. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front Alignment > Page 4803 13. Jounce vehicle an equal number of times and verify rear camber setting. When vehicle is at correct setting, torque rear strut clevis brackets to 70 ft.-lbs. TOE Rear wheel toe must be set prior to setting front wheel toe. Proceed as follows: 1. Center steering wheel and lock in place using a steering wheel clamp. Rear Lateral Link Toe Setting 2. Loosen nuts on attaching bolts for left and right lateral links to rear crossmember. Rear Wheel Toe Adjustment Cams 3. Rotate lateral link adjustment cams until preferred rear toe specification is obtained. 4. While holding toe adjustment cams from turning, tighten right and left lateral links to rear crossmember attaching bolt nuts. This will securely hold adjustment cams in position. 5. Hold lateral link attaching bolt and adjustment cam from turning and torque lateral link attaching bolt to 70 ft.-lbs. 6. Loosen front inner tie rod end jam nuts, then grasp inner tie rods at serration. 7. Rotate inner tie rods of steering gear and set front toe specifications. 8. Torque tie rod lock nuts to 45 ft.-lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 4810 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 4811 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 4812 Power Steering Pressure Switch: Description and Operation Fig. 15 Power Steering Pressure Switch PURPOSE On vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. The pressure switch improves vehicle idle quality, by controlling engine idle speed when required. The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed is increased. This increase in engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The power steering pressure switch is mounted directly to the power steering gear on vehicles requiring its usage. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z12 provides ground for the power steering pressure switch. The grounding point for circuit Z12 is the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 4813 Power Steering Pressure Switch: Testing and Inspection Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Customer Interest for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension Popping/Creaking Noises Front Steering Knuckle: Customer Interest Front Suspension - Popping/Creaking Noises NO: 02-02-97 Rev. A GROUP: Front Suspension EFFECTIVE DATE: Dec. 15, 1997 SUBJECT: Popping/Creaking Noise in Front Suspension THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-02-97 DATED FEBRUARY 28, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL FRONT SUSPENSION NOISE DIAGNOSTICS/REPAIRS HAVE BEEN ADDED. THE ADDITIONS ARE HIGHLIGHTED WITH ASTERISKS. MODELS: 1995 - 1998 (PL) Neon SYMPTOM/CONDITION: **A popping noise from the front suspension may be experienced while: ^ Going in reverse or forward with the steering wheel turned completely in one direction (parking lot maneuvers). ^ Shifting from drive to reverse, reverse to drive, etc. ^ Pulling in/out of driveway. ^ Large dips/bumps in the road such as speed bumps. ** DIAGNOSIS: If the customer describes the front suspension noise in conditions such as those described above, perform the Repair Procedure. PARTS REQUIRED: NOTE: THE 1995 NEONS BUILT IN 1994 USED 13" KNUCKLE ASSEMBLIES WITH 13" OR 14" WHEELS. LATER BUILT VEHICLES HAVE 13" OR 14" KNUCKLE ASSEMBLIES TO MATCH ORIGINAL WHEEL SIZE. TO DETERMINE THE PROPER KNUCKLE SIZE, COUNT THE STUDS ON THE HUB THEN REFER TO THE PARTS LIST PROVIDED IN THIS BULLETIN. CAUTION: DO NOT USE THE WHEEL SIZE TO DETERMINE PROPER KNUCKLE PART NUMBERS. REPAIR PROCEDURE: **This bulletin involves inspecting/replacing as needed both front wheel bearings and steering knuckles, front upper strut mounts, engine mounts, and lubing the driveshafts.** Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Customer Interest for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension Popping/Creaking Noises > Page 4823 **NOTE: USE TABLE TO DETERMINE WHICH STEPS TO PERFORM BASED ON VEHICLE BUILD DATE AND IF TECHNICAL SERVICE BULLETIN 02-02-97, DATED FEBRUARY 28, 1997 HAS BEEN PERFORMED.** NOTE: ALL FRONT KNUCKLE/BEARING/HUB REPAIR PROCEDURES FOR STEPS 1 THROUGH 5, CAN BE FOUND IN THE 1998 NEON SERVICE MANUAL (PUBLICATION NUMBER 81-270-8025) GROUP 2 (SUSPENSION). 1. Remove both left and right front knuckle/bearing/hub assemblies. 2. Press the hub out of the old knuckle/bearing/hub assemblies. 3. Press the old hubs into the new knuckle/bearing assemblies. **4. Before the knuckle/bearing/hub assemblies are installed on the vehicle, put a small amount of grease (Wheel Bearing Lube - p/n 04318064) on the entire face of the driveshaft that makes contact with the hub bearing assembly (Figure 1).** 5. Install both left and right front knuckle/bearing/hub assemblies. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Customer Interest for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension Popping/Creaking Noises > Page 4824 **6. Replace the upper strut mount by following the procedures in the 1998 Neon Service Manual (Publication No. 81-270-8025), Removal/Installation, pages 2-16 to 2-17, and Assembly/Disassembly procedures 1 thru 5 on pages 2-30 to 2-31 (Figure 2). The torque for the new upper strut mount nuts is 61 Nm (45 ft.lbs).** **7. Remove and replace the right engine mount as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) (SOHC - pg 9-18)(DOHC - pg 9-64). After replacing the right engine mount, squirt enough grease (Silicone Spray - p/n 04318070) between the mount snubber and the engine bracket to fill the gap (Figure 3).** NOTE: IF THE SILICONE SPRAY (P/N 04318070) IS NOT AVAILABLE, ANOTHER SILICONE SPRAY MAY BE USED. HOWEVER THE SUBSTITUTE SILICONE SPRAY MUST NOT BE PETROLEUM BASED. **8. Inspect and tighten remaining suspension components to specification; repair or replace as needed.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-05-30-93 Knuckles and Mounts - Replace - All 2.9 Hrs. 02-05-39-91 Upper Strut Mounts and Engine Mount - Replace 1.3 Hrs. 09-40-21-91 Engine Mount Replace 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension - Popping/Creaking Noises Front Steering Knuckle: All Technical Service Bulletins Front Suspension - Popping/Creaking Noises NO: 02-02-97 Rev. A GROUP: Front Suspension EFFECTIVE DATE: Dec. 15, 1997 SUBJECT: Popping/Creaking Noise in Front Suspension THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-02-97 DATED FEBRUARY 28, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL FRONT SUSPENSION NOISE DIAGNOSTICS/REPAIRS HAVE BEEN ADDED. THE ADDITIONS ARE HIGHLIGHTED WITH ASTERISKS. MODELS: 1995 - 1998 (PL) Neon SYMPTOM/CONDITION: **A popping noise from the front suspension may be experienced while: ^ Going in reverse or forward with the steering wheel turned completely in one direction (parking lot maneuvers). ^ Shifting from drive to reverse, reverse to drive, etc. ^ Pulling in/out of driveway. ^ Large dips/bumps in the road such as speed bumps. ** DIAGNOSIS: If the customer describes the front suspension noise in conditions such as those described above, perform the Repair Procedure. PARTS REQUIRED: NOTE: THE 1995 NEONS BUILT IN 1994 USED 13" KNUCKLE ASSEMBLIES WITH 13" OR 14" WHEELS. LATER BUILT VEHICLES HAVE 13" OR 14" KNUCKLE ASSEMBLIES TO MATCH ORIGINAL WHEEL SIZE. TO DETERMINE THE PROPER KNUCKLE SIZE, COUNT THE STUDS ON THE HUB THEN REFER TO THE PARTS LIST PROVIDED IN THIS BULLETIN. CAUTION: DO NOT USE THE WHEEL SIZE TO DETERMINE PROPER KNUCKLE PART NUMBERS. REPAIR PROCEDURE: **This bulletin involves inspecting/replacing as needed both front wheel bearings and steering knuckles, front upper strut mounts, engine mounts, and lubing the driveshafts.** Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension - Popping/Creaking Noises > Page 4830 **NOTE: USE TABLE TO DETERMINE WHICH STEPS TO PERFORM BASED ON VEHICLE BUILD DATE AND IF TECHNICAL SERVICE BULLETIN 02-02-97, DATED FEBRUARY 28, 1997 HAS BEEN PERFORMED.** NOTE: ALL FRONT KNUCKLE/BEARING/HUB REPAIR PROCEDURES FOR STEPS 1 THROUGH 5, CAN BE FOUND IN THE 1998 NEON SERVICE MANUAL (PUBLICATION NUMBER 81-270-8025) GROUP 2 (SUSPENSION). 1. Remove both left and right front knuckle/bearing/hub assemblies. 2. Press the hub out of the old knuckle/bearing/hub assemblies. 3. Press the old hubs into the new knuckle/bearing assemblies. **4. Before the knuckle/bearing/hub assemblies are installed on the vehicle, put a small amount of grease (Wheel Bearing Lube - p/n 04318064) on the entire face of the driveshaft that makes contact with the hub bearing assembly (Figure 1).** 5. Install both left and right front knuckle/bearing/hub assemblies. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension - Popping/Creaking Noises > Page 4831 **6. Replace the upper strut mount by following the procedures in the 1998 Neon Service Manual (Publication No. 81-270-8025), Removal/Installation, pages 2-16 to 2-17, and Assembly/Disassembly procedures 1 thru 5 on pages 2-30 to 2-31 (Figure 2). The torque for the new upper strut mount nuts is 61 Nm (45 ft.lbs).** **7. Remove and replace the right engine mount as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) (SOHC - pg 9-18)(DOHC - pg 9-64). After replacing the right engine mount, squirt enough grease (Silicone Spray - p/n 04318070) between the mount snubber and the engine bracket to fill the gap (Figure 3).** NOTE: IF THE SILICONE SPRAY (P/N 04318070) IS NOT AVAILABLE, ANOTHER SILICONE SPRAY MAY BE USED. HOWEVER THE SUBSTITUTE SILICONE SPRAY MUST NOT BE PETROLEUM BASED. **8. Inspect and tighten remaining suspension components to specification; repair or replace as needed.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-05-30-93 Knuckles and Mounts - Replace - All 2.9 Hrs. 02-05-39-91 Upper Strut Mounts and Engine Mount - Replace 1.3 Hrs. 09-40-21-91 Engine Mount Replace 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 4832 Front Steering Knuckle: Service and Repair 1. Remove cotter pin, castle nut and hub nut while vehicle is still on floor with brakes applied. 2. Raise and support vehicle, then remove front tire and wheel assembly. 3. Remove front disc brake caliper and place aside. CAUTION: Do not let caliper assembly hang by hose. 4. Remove front disc brake, then disconnect tie rod from steering knuckle using removal tool No. MB-990635, or equivalent. 5. Separate ball joint stud from steering knuckle by prying down on lower control arm. Ensure ball joint seal is not damage. 6. Pull steering knuckle assembly out and away from outer CV joint of driveshaft assembly. 7. Remove two steering knuckle to strut damper attaching bolts, then the steering knuckle and hub/bearing assembly from vehicle. 8. Reverse procedure to install. Torque clamp bolt to 70 ft.-lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair 1. Ensure power steering fluid reservoir is full, then start and run engine. If fluid level drops after engine has been run, fill and run again until level remains constant. 2. Raise and support front of vehicle, then start engine and turn steering wheel slowly from stop to stop. 3. Stop engine and add fluid as necessary, then lower vehicle and restart engine. 4. Turn steering wheel slowly from stop to stop, then stop engine again and add fluid as necessary. 5. Inspect fluid condition. If it appears extremely foamy, do not disturb vehicle for several minutes, then repeat bleed procedure. Inspect for leaks. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Fluid: Customer Interest Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 4845 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4851 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4852 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4853 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Fluid: All Technical Service Bulletins Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 4858 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Fluid: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4864 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4865 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4866 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Pump: Customer Interest Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 4875 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist Power Steering Pump: Customer Interest Drive Belt - Momentary Loss of Power Steering Assist NO: 07-04-97 GROUP: Accessory Belt DATE: Jun. 6, 1997 SUBJECT: Momentary Loss Of Power Steering Assist When Driving Through Heavy Rain - Deep Puddles MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Momentary loss of power steering assist when driving through heavy rain and/or deep puddles. Loss of power steering is caused by water intrusion into the accessory drive belt area. DIAGNOSIS: Inspect the belt for glazing and/or cracks, if either is found replace the belt following the repair procedure found in the 1997 Neon Service Manual (Publication No. 81-270-7025) Page 7-21. Determine the road conditions the driver of the vehicle was encountering at the time the loss of power assist was experienced. If the driver indicates the loss of power steering assist was during times of heavy rain or deep puddles, perform the Repair Procedure. PARTS REQUIRED: AR(1) 04612247 Belt, Accessory Drive - Power steering and A/C Compressor REPAIR PROCEDURE: This bulletin involves correcting the tension on the power steering accessory drive belt. 1. Loosen the power steering pump locking bolts A and B and pivot bolt C (Illustration) to allow adjustment of belt tension. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist > Page 4880 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square hole "D" on the power steering pivot bracket. Adjust the tension as follows: Belt tension with no belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 100 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). Belt tension with belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 135 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). C. Start the engine and allow the vehicle to idle for 15 minutes to allow the belt to seat. D. Repeat the belt tensioning procedure, set belt tension to 135 lb. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-11-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Pump: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4886 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4887 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4888 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures Power Steering Pump: All Technical Service Bulletins Power Steering System - Noise in Cold Temperatures NO: 19-03-98 GROUP: Steering DATE: Mar. 6, 1998 SUBJECT: Cold Start Power Steering Noise MODELS: 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1998 1999 (LH) Concorde/Intrepid/LHS/300M 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 1999 LH VEHICLES BUILT THROUGH JULY 31, 1998 (MDH 0731XX). SYMPTOM/CONDITION: Power steering system noise following cold engine starts in low ambient temperatures. DIAGNOSIS: The noise typically occurs in -12 C (10 F) or below ambient temperatures and lasts less than one minute in duration. The noise occurs with and without steering wheel input and increases in duration and intensity as the ambient temperature decreases below -12 C (10 F). The power steering noise may remain present until the fluid begins to warm which occurs as the fluid cycles through the power steering system with the engine running. The lower the ambient temperature, the longer it will take for the fluid to warm. If the power steering system demonstrates this symptom/condition and operates normally when the fluid is warm, perform the Repair Procedure. PARTS REQUIRED: 3 05010304AA Power Steering Fluid, Quart REPAIR PROCEDURE: This bulletin involves replacing the original power steering fluid (MS-5931) with new power steering fluid (MS-9933) which has improved cold temperature properties. NOTE: THE NEW POWER STEERING FLUID (MS-9933) WILL DECREASE THE TEMPERATURE AT WHICH THE NOISE OCCURS AND REDUCE BOTH THE DURATION AND INTENSITY OF THE NOISE. HOWEVER, THE POWER STEERING NOISE AT COLD ENGINE START MAY NOT BE TOTALLY ELIMINATED ON ALL VEHICLES OR UNDER SEVERE COLD AMBIENT TEMPERATURES. 1. With the engine at operating temperatures and not running, remove the power steering return hose from the power steering cooler (Neon at the reservoir). Allow the power steering system to drain. 2. Raise the front wheels off the ground. 3. Purge the fluid from the steering gear by slowly turning the steering wheel lock to lock several times. 4. Reattach the power steering return hose to the power steering cooler (Neon to the reservoir). 5. Fill the power steering system to the max cold level with the new power steering fluid, p/n 05010304AA. Leave cap off. 6. With the engine not running, slowly turn the steering wheel lock to lock 3-4 times. Top off fluid level to max cold if necessary. 7. Start the engine and turn the steering wheel lock to lock 3-4 times. 8. Shut off engine and repeat steps 1-5 to purge air from the power steering system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 19-03-98 > Mar > 98 > Power Steering System - Noise in Cold Temperatures > Page 4893 9. With the engine not running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary. 10. Start the engine. With the engine idling, maintain fluid level. 11. With The engine running, slowly turn the steering wheel lock to lock at least 20 times. Top off fluid level to max cold if necessary and reinstall the reservoir cap. 12. Return the steering wheel to center position. Lower front wheels to ground. 13. With engine running, slowly turn the steering wheel lock to lock to verify smooth, low noise power assist operation and no system leaks. Recheck for proper fluid level. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-97 0.4 Hrs. FAILURE CODE: P8-New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist Power Steering Pump: All Technical Service Bulletins Drive Belt - Momentary Loss of Power Steering Assist NO: 07-04-97 GROUP: Accessory Belt DATE: Jun. 6, 1997 SUBJECT: Momentary Loss Of Power Steering Assist When Driving Through Heavy Rain - Deep Puddles MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Momentary loss of power steering assist when driving through heavy rain and/or deep puddles. Loss of power steering is caused by water intrusion into the accessory drive belt area. DIAGNOSIS: Inspect the belt for glazing and/or cracks, if either is found replace the belt following the repair procedure found in the 1997 Neon Service Manual (Publication No. 81-270-7025) Page 7-21. Determine the road conditions the driver of the vehicle was encountering at the time the loss of power assist was experienced. If the driver indicates the loss of power steering assist was during times of heavy rain or deep puddles, perform the Repair Procedure. PARTS REQUIRED: AR(1) 04612247 Belt, Accessory Drive - Power steering and A/C Compressor REPAIR PROCEDURE: This bulletin involves correcting the tension on the power steering accessory drive belt. 1. Loosen the power steering pump locking bolts A and B and pivot bolt C (Illustration) to allow adjustment of belt tension. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 07-04-97 > Jun > 97 > Drive Belt - Momentary Loss of Power Steering Assist > Page 4898 2. Using a 1/2" breaker bar, adjust belt tension by applying torque to the square hole "D" on the power steering pivot bracket. Adjust the tension as follows: Belt tension with no belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 100 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). Belt tension with belt replacement: A. Using the Belt Tension Gauge Special Tool Kit C-4162, adjust the belt tension to 135 lb. B. Tighten in order, first tighten the locking bolt A to 27 Nm (20 ft. lbs) then, bolt B to 27 Nm (20 ft. lbs). Finally tighten the pivot bolt C to 54 Nm (40 ft. lbs). C. Start the engine and allow the vehicle to idle for 15 minutes to allow the belt to seat. D. Repeat the belt tensioning procedure, set belt tension to 135 lb. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-11-90 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage Power Steering Pump: All Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4904 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4905 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Pump: > 19-005-03 > Aug > 03 > Steering - Power Steering Fluid Usage > Page 4906 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Measurements Given are in ft-lbs unless otherwise specified. Outer Tie Rod End Locknut ................................................................................................................. ..................................................................... 45 ft-lbs Power Steering Hose Tube Nuts ......................................................................................................... ...................................................................... 22 ft-lbs Power Steering Pump Relief Valve Ball Seat ........................................................................................................................................................... 48 in-lbs Pressure Hose Banjo Bolt ................................................................................................................... ...................................................................... 25 ft-lbs Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 4909 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Power Steering Pump Pressure, psi Test Valve Open [01].................................................................. ................................................................................................................................... 50-80 Test Valve Closed [02]................................................................................................................................. ......................................................... 1195-1293 Max Relief Pressure ................................................ .............................................................................................................................................. 1195-1293 Output Flow [03]................................................................................................................. ...................................................................................... 1.3-1.9 [01] -- Initial pressure. [02] -- Do not leave valve closed for more than five seconds. [03] -- At 1500 RPM & minimum pressure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 4910 Power Steering Pump: Testing and Inspection Fig.4 Data Link Connector The diagnostic testing procedure provided in this section applies only to speed proportional steering systems. Diagnostic Trouble Code (DTC) 35 applies only to the speed proportional steering test.A DRB or equivalent scan tool is necessary to access the speed proportional power steering diagnostic trouble codes. Connect DRB scan tool or equivalent to data link connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 4911 Fig.5 Speed Proportional Steering Test Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 4912 Fig.6 Test Verification Procedure The diagnostic cycle begins when the ignition is turned to the On position. The condition required to set Diagnostic Trouble Code 35 is driving the vehicle in OD and achieving 1st through 4th electronically modulated converter clutch (EMCC). After completing diagnostic tests perform verification procedures, when required. Fig.7 Speed Proportional Power Steering Wiring Diagram Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 4913 Fig.8 Transmission Control Module Wiring Diagram Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Removal and Installation Power Steering Pump: Service and Repair Power Steering Pump Removal and Installation 1. Disconnect battery ground cable, then the power steering pressure hose from power steering pump. 2. Remove power steering fluid supply hose to power steering suction fitting, then the power steering fluid supply hose. 3. Remove two power steering pump to cast bracket mounting and adjusting bolts. 4. Loosen bolt attaching front power steering pump mounting bracket to front engine mount only far enough to slide bracket from behind bolt. 5. Remove drive belt, then the power steering pump and bracket as an assembly. 6. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Removal and Installation > Page 4916 Power Steering Pump: Service and Repair Power Steering Pump Serviceability The power steering pump is not serviceable except for the reservoirs and related components, filler cap/dipstick and any oil seals other than the pump shaft seal. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications Power Steering Pressure Switch: Electrical Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Electrical Specifications > Page 4922 Power Steering Pressure Switch: Pressure, Vacuum and Temperature Specifications The power steering pressure switch is a normally closed switch. The power steering pressure switch opens when pressure exceeds 500 psi. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 4923 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 4924 Power Steering Pressure Switch: Description and Operation Fig. 15 Power Steering Pressure Switch PURPOSE On vehicles equipped with power steering, a power steering pressure switch is used to improve the vehicle's idle quality. The pressure switch improves vehicle idle quality, by controlling engine idle speed when required. The switch (Fig. 15) provides an input to the PCM during periods of high pump load and low engine RPM; such as during parking maneuvers. OPERATION The pressure switch functions by signaling the power train control module, that the power steering system is putting additional load on the engine. This type of condition exists when turning the front tires of the vehicle, when the vehicle is stationary and the engine is at idle speed. When this condition is sensed by the power train control module, through a signal from the power steering pressure switch, engine idle speed is increased. This increase in engine idle speed compensates for the additional load, thus maintaining the require engine idle speed and idle quality. When power steering pump pressure exceeds 2,758 kPa (400 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling. When pump pressure is low, the switch is closed. The power steering pressure switch is mounted directly to the power steering gear on vehicles requiring its usage. CIRCUIT OPERATION The power steering pressure switch opens and closes circuit K10 between the Powertrain Control Module (PCM) and ground. Circuit K10 connects to cavity 45 of the PCM connector. Circuit Z12 provides ground for the power steering pressure switch. The grounding point for circuit Z12 is the left side of the radiator closure panel. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 4925 Power Steering Pressure Switch: Testing and Inspection Chrysler provides complete testing for this component under Powertrain Management/Computers and Control Systems/Testing and Inspection. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 WARNINGS: - 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. - 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, use proper and safe service procedures . Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: 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 disarm the system. NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). 1. Disconnect and isolate the battery negative (ground) cable. 2. 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 air-bag deployment and possible personal injury. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 4932 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming WARNING: Before attempting to diagnose, remove or install any airbag system components, first disconnect and isolate battery ground cable, then wait at least 2 minutes prior the performing any service. - Failure to do so may result in airbag deployment or personal injury. 1. Connect the scan tool to the Data Link connector which is located on the left side kick panel just above the hood release. 2. Turn the ignition key to the ON position. Exit vehicle with the scan tool. Use the latest version of the diagnostic cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative remote terminal. 4. Using the scan tool, read and record the active diagnostic trouble code data. 5. Read and record any stored diagnostic trouble codes. 6. Refer to Powertrain Management/Computers and Controls/Body Control Module if any diagnostic trouble codes are found in Step 4 and Step 5. 7. Erase stored diagnostic trouble codes if there are no active diagnostic trouble codes. If problems remain, diagnostic trouble codes will not erase. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. If the airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest for Steering Gear: > 19-04-96A > Jan > 97 > Steering Gear - Whistle/Hiss On Right Turns Steering Gear: Customer Interest Steering Gear - Whistle/Hiss On Right Turns NO: 19-04-96 Rev. A GROUP: Steering EFFECTIVE DATE: Jan. 10, 1997 SUBJECT: Steering Noise When Turning Right THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-04-96, DATED AUGUST 9, 1996 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE NEON HAS BEEN ADDED. ALL CHANGES TO THE PROCEDURE ARE MARKED WITH **ASTERISKS** MODELS: 1995 - 1996 (JA) Breeze/Cirrus/Stratus **1995 - 1997 (PL/1) Neon** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH STANDARD STEERING, SALES CODE SBA. SYMPTOM/CONDITION: Whistle and/or hiss noise from steering gear when making right turns. DIAGNOSIS: To verify noise, heat the power steering fluid to 155-165° F by holding engine speed at 2000-3000 rpm. Turn the steering wheel to the left and hit the stop ten times. Turn the wheel to the right and hit the stop ten times. Repeat this for a total of three times. Return the steering wheel to the center position and let the engine idle. Very slowly, turn the wheel to the right. Periodically stop and move the wheel back very slowly. Listen for a high pitched "whistle". If a "whistle" exists it can be maintained by holding the wheel at that position. Return the wheel to the center position. Turn the wheel to the right at a speed of approximately 12 rpm. Listen for a constant "hiss" noise. If either of these noises exists during right hand turns, perform the Repair Procedure. PARTS REQUIRED: 1 04886335AA Gear Assembly, Power Steering (Breeze/Cirrus/Stratus) **1 04897187AA Gear Assembly, Power Steering (Neon)** REPAIR PROCEDURE: This bulletin involves replacing the power steering gear with a revised part. Remove and replace the power steering gear as described on page 19-36 of the 1996 Breeze/Cirrus/Stratus Service Manual (Publication No. 81-270-6121). **For Neon refer to the 1997 Neon Service Manual (Publication No. 81-270-7025) beginning on page 19-29.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-93 2.7 Hrs. 1995-1996 (Breeze/Cirrus/Stratus) 19-00-02-93 1.8 Hrs. 1995-1997 (Neon) FAILURE CODE: 68 - Noisy Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-04-96A > Jan > 97 > Steering Gear - Whistle/Hiss On Right Turns Steering Gear: All Technical Service Bulletins Steering Gear - Whistle/Hiss On Right Turns NO: 19-04-96 Rev. A GROUP: Steering EFFECTIVE DATE: Jan. 10, 1997 SUBJECT: Steering Noise When Turning Right THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-04-96, DATED AUGUST 9, 1996 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE NEON HAS BEEN ADDED. ALL CHANGES TO THE PROCEDURE ARE MARKED WITH **ASTERISKS** MODELS: 1995 - 1996 (JA) Breeze/Cirrus/Stratus **1995 - 1997 (PL/1) Neon** NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH STANDARD STEERING, SALES CODE SBA. SYMPTOM/CONDITION: Whistle and/or hiss noise from steering gear when making right turns. DIAGNOSIS: To verify noise, heat the power steering fluid to 155-165° F by holding engine speed at 2000-3000 rpm. Turn the steering wheel to the left and hit the stop ten times. Turn the wheel to the right and hit the stop ten times. Repeat this for a total of three times. Return the steering wheel to the center position and let the engine idle. Very slowly, turn the wheel to the right. Periodically stop and move the wheel back very slowly. Listen for a high pitched "whistle". If a "whistle" exists it can be maintained by holding the wheel at that position. Return the wheel to the center position. Turn the wheel to the right at a speed of approximately 12 rpm. Listen for a constant "hiss" noise. If either of these noises exists during right hand turns, perform the Repair Procedure. PARTS REQUIRED: 1 04886335AA Gear Assembly, Power Steering (Breeze/Cirrus/Stratus) **1 04897187AA Gear Assembly, Power Steering (Neon)** REPAIR PROCEDURE: This bulletin involves replacing the power steering gear with a revised part. Remove and replace the power steering gear as described on page 19-36 of the 1996 Breeze/Cirrus/Stratus Service Manual (Publication No. 81-270-6121). **For Neon refer to the 1997 Neon Service Manual (Publication No. 81-270-7025) beginning on page 19-29.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-00-02-93 2.7 Hrs. 1995-1996 (Breeze/Cirrus/Stratus) 19-00-02-93 1.8 Hrs. 1995-1997 (Neon) FAILURE CODE: 68 - Noisy Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Power Steering Gear Steering Gear: Specifications Power Steering Gear Outer Tie Rod End Locknut ................................................................................................................. ...................................................................... 45 ft-lbs Power Steering Hose Tube Nuts .................... ............................................................................................................................................................ 22 ft-lbs Power Steering Pump Relief Valve Ball Seat ............................................................................................................................................................ 48 in-lbs Pressure Hose Banjo Bolt ..................................................................................................... ..................................................................................... 25 ft-lbs Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Power Steering Gear > Page 4948 Steering Gear: Specifications Manual Steering Gear Inner-To-Outer Tie Rod Jam Nut ......................................................................................................... ..................................................................... 45 ft-lbs Tie Rod End To Steering Knuckle Nut ............. ........................................................................................................................................................ 45 ft-lbs Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 4949 Steering Gear: Adjustments The rack and pinion power steering gear used on these models should not be serviced or adjusted. If a malfunction or oil leak should occur, the complete steering gear should be replaced. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service Steering Gear: Service and Repair Manual Steering Gear Service The manual steering gear assembly should not be serviced or adjusted. In the event of damage or a malfunction such as an oil leak, the entire assembly should be replaced. However, the inner tie rod boots and outer tie rod ends can be replaced as follows: 1. Loosen inner to outer tie rod jam nut; then, if assembly is still in vehicle, remove nut securing outer tie rod end to steering knuckle. 2. Separate outer tie rod from steering knuckle using remover tool No. MB990635, or equivalent, then expand tie rod boot to inner tie rod clamp using suitable pliers. 3. Remove clamp from steering gear boot, then expand boot snorkel clamp using suitable pliers. 4. Slip clamp from boot, then remove inner tie rod boot to steering gear clamp. 5. Using a small screwdriver, gently lift lip of inner tie rod boot out of retaining groove in steering gear, then remove boot from gear. 6. Reverse procedure to install, noting the following: a. Lubricate inner tie rod boot groove and boot end seal with suitable silicone lubricant. b. Tighten inner to outer tie rod jam nut and outer tie rod end to steering knuckle nut to specifications. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 4952 Steering Gear: Service and Repair Steering Gear Replacement Manual Steering Gear Replacement Manual Steering Gear Assembly 1. Disconnect steering gear coupler from steering column shaft coupler. 2. Raise and support vehicle, then remove both front wheel and tire assemblies. 3. Remove engine/transaxle dampener. 4. Remove attaching nuts from both tie rod ends. 5. Remove both tie rod end studs from steering knuckle using remover tool No. MB-990635, or equivalent, then disconnect wiring harness connector from power steering fluid pressure switch. 6. Remove power steering pressure and return hose routing bracket from front suspension crossmember. 7. Remove power steering fluid, pressure and return hoses from power steering gear assembly. 8. Scribe a line marking the location of where front suspension crossmember is mounted against body. 9. Position a transaxle jack beneath the center of the front suspension crossmember, then remove two bolts attaching front suspension crossmember to frame rails of vehicle. 10. Loosen both rear bolts and lower control arm to body of vehicle. 11. Using transaxle jack lower front suspension crossmember enough to allow steering gear to be removed. 12. Remove four bolts attaching steering gear assembly to front suspension crossmember, then the steering gear assembly. 13. Reverse procedure to install. Power Steering Gear Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 4953 Power Steering Gear Assembly 1. Disconnect steering gear coupler from steering column shaft coupler. 2. Raise and support vehicle, then remove both front wheel and tire assemblies. 3. Remove engine/transaxle dampener. 4. Remove attaching nuts from both tie rod ends. 5. Remove both tie rod end studs from steering knuckle using remover tool No. MB-990635, or equivalent, then disconnect wiring harness connector from power steering fluid pressure switch. 6. Remove power steering pressure and return hose routing bracket from front suspension crossmember. 7. Remove power steering fluid, pressure and return hoses from power steering gear assembly. 8. Scribe a line marking the location of where front suspension crossmember is mounted against body. 9. Position a transaxle jack beneath the center of the front suspension crossmember, then remove two bolts attaching front suspension crossmember to frame rails of vehicle. 10. Loosen both rear bolts and lower control arm to body of vehicle. 11. Using transaxle jack lower front suspension crossmember enough to allow steering gear to be removed. 12. Remove four bolts attaching steering gear assembly to front suspension crossmember, then the steering gear assembly. 13. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 19-02-99A > Oct > 99 > Steering Wheel/Steering Column Clunking Or Rattle Technical Service Bulletin # 19-02-99A Date: 991022 Steering Wheel/Steering Column - Clunking Or Rattle NUMBER: 19-02-99 Rev. A GROUP: Steering DATE: Oct. 22, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-01-98 DATED FEBRUARY 6, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003) AND 19-02-99 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISION ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS CHANGES. SUBJECT: Clunking Or Rattle In Steering Wheel/Steering Column OVERVIEW: This bulletin involves resetting the steering column preload. MODELS: 1995 - **2000** (JA) Breeze/Cirrus/Stratus 1996 - **2000** (JX) Sebring Convertible 1995 - 2000 (PL) Neon SYMPTOM/CONDITION: Steering wheel/column clunking or rattle is more frequent while hitting bumps or on hard turns. DIAGNOSIS: Inspect steering wheel/column for any rattle or clunking noise. If symptoms exist perform the Repair Procedure. PARTS REQUIRED: 1 05015627AA Bolt, Steering Gear Coupler Retaining, PL 1 **06506112AA Bolt, Steering Gear Coupler Retaining, JA/JX** 1 **06036212AA Clip, Steering Gear Coupler Retaining, JA/JX** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-20-12-96 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. NOTE: THE VEHICLE WHEELS NEED TO BE ON THE GROUND (SUPPORTING VEHICLE WEIGHT) WHEN PERFORMING THIS REPAIR. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with a tilt steering column, adjust to the full up position. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 19-02-99A > Oct > 99 > Steering Wheel/Steering Column Clunking Or Rattle > Page 4962 3. Detach the lower steering column intermediate shaft from the steering gear shaft (Figure 1). This allows the steering column preload to reset. 4. Re-attach the intermediate shaft to the steering gear using a new pinch bolt from the Parts Required section of this bulletin. Tighten the bolt to 27 N.m (240 in. lbs.). 5. Install the retaining clip/pin into the pinch bolt (Figure 1). NOTE: A NEW STEERING GEAR COUPLING PINCH BOLT MUST BE USED WHEN RE-ATTACHING THE INTERMEDIATE SHAFT TO THE STEERING GEAR. THIS BOLT HAS A LOCKING PATCH THAT IS DESTROYED WHEN THE NUT IS REMOVED. 6. Connect the battery negative cable and reset the clock. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 19-02-99A > Oct > 99 > Steering Wheel/Steering Column - Clunking Or Rattle Technical Service Bulletin # 19-02-99A Date: 991022 Steering Wheel/Steering Column - Clunking Or Rattle NUMBER: 19-02-99 Rev. A GROUP: Steering DATE: Oct. 22, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-01-98 DATED FEBRUARY 6, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003) AND 19-02-99 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISION ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS CHANGES. SUBJECT: Clunking Or Rattle In Steering Wheel/Steering Column OVERVIEW: This bulletin involves resetting the steering column preload. MODELS: 1995 - **2000** (JA) Breeze/Cirrus/Stratus 1996 - **2000** (JX) Sebring Convertible 1995 - 2000 (PL) Neon SYMPTOM/CONDITION: Steering wheel/column clunking or rattle is more frequent while hitting bumps or on hard turns. DIAGNOSIS: Inspect steering wheel/column for any rattle or clunking noise. If symptoms exist perform the Repair Procedure. PARTS REQUIRED: 1 05015627AA Bolt, Steering Gear Coupler Retaining, PL 1 **06506112AA Bolt, Steering Gear Coupler Retaining, JA/JX** 1 **06036212AA Clip, Steering Gear Coupler Retaining, JA/JX** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-20-12-96 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. NOTE: THE VEHICLE WHEELS NEED TO BE ON THE GROUND (SUPPORTING VEHICLE WEIGHT) WHEN PERFORMING THIS REPAIR. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is equipped with a tilt steering column, adjust to the full up position. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 19-02-99A > Oct > 99 > Steering Wheel/Steering Column - Clunking Or Rattle > Page 4968 3. Detach the lower steering column intermediate shaft from the steering gear shaft (Figure 1). This allows the steering column preload to reset. 4. Re-attach the intermediate shaft to the steering gear using a new pinch bolt from the Parts Required section of this bulletin. Tighten the bolt to 27 N.m (240 in. lbs.). 5. Install the retaining clip/pin into the pinch bolt (Figure 1). NOTE: A NEW STEERING GEAR COUPLING PINCH BOLT MUST BE USED WHEN RE-ATTACHING THE INTERMEDIATE SHAFT TO THE STEERING GEAR. THIS BOLT HAS A LOCKING PATCH THAT IS DESTROYED WHEN THE NUT IS REMOVED. 6. Connect the battery negative cable and reset the clock. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 4969 Steering Wheel: Service and Repair 1. Disconnect battery ground cable. 2. Place front wheels straight forward. 3. Rotate steering wheel 180° clockwise. 4. Lock steering with column lock cylinder. 5. Remove speed control switch and connector. 6. Remove air bag module attaching bolts from rear of steering wheel. 7. Lift module and disconnect wiring. 8. Remove steering wheel retaining nut and vibration damper if equipped. 9. With appropriate tool, remove steering wheel while avoiding damage to clockspring wiring. 10. Reverse procedure to install, noting the following: a. Install steering wheel ensuring flats on hub align with clockspring. b. Torque steering wheel mounting nut to 45 ft.-lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Service and Repair Tie Rod Boot: Service and Repair 1. Loosen jam nut, then disconnect tie rod from steering knuckle. 2. Remove outer tie rod and jam nut, then the outer boot clamp. 3. Use pliers to expand boot snorkel clamp, then slide clamp onto breather tube. 4. Remove inner boot clamp, then mark breather tube location and remove boot. 5. Reverse procedure to install, noting the following: a. Line up mark and breather tube location. b. Install boot over housing lip with hole in boot aligned with breather tube. c. Lubricate outer boot groove with silicone prior to installing outer boot clamp and ensure boot is not twisted. d. Tighten tie rod jam nut to specifications. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications Tie Rod Torque Tie Rod Torque Tie Rod End Attaching Nut 61 Nm Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Page 4977 Tie Rod End: Service and Repair 1. Loosen jam nut, then disconnect tie rod from steering knuckle. 2. Remove outer tie rod and jam nut, then the outer boot clamp. 3. Use pliers to expand boot snorkel clamp, then slide clamp onto breather tube. 4. Remove inner boot clamp, then mark breather tube location and remove boot. 5. Reverse procedure to install, noting the following: a. Line up mark and breather tube location. b. Install boot over housing lip with hole in boot aligned with breather tube. c. Lubricate outer boot groove with silicone prior to installing outer boot clamp and ensure boot is not twisted. d. Tighten tie rod jam nut to specifications. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint Ball Joint: Testing and Inspection Lower Ball Joint Ball Joint Wear Inspection With weight of vehicle resting on wheel, grasp grease fitting and with no mechanical assistance or added force, attempt to move grease fitting. If the ball joint is worn the grease fitting will move easily. If movement is noted, replacement of ball joint is recommended. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint > Page 4983 Ball Joint: Testing and Inspection Upper Ball Joint Ball Joint Wear Inspection With weight of vehicle resting on wheel, grasp grease fitting and with no mechanical assistance or added force, attempt to move grease fitting. If the ball joint is worn the grease fitting will move easily. If movement is noted, replacement of ball joint is recommended. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Replacement Ball Joint: Service and Repair Lower Ball Joint Replacement 1. Remove lower control arm following procedure outlined under Control Arm/ Control Arm Replacement. 2. Using screwdriver or other suitable tool, pry ball joint seal boot off ball joint assembly. 3. Position receiving cup tool No. 6758, or equivalent, to support lower control arm while receiving ball joint assembly. 4. Install receiver/installer tool No. 6804, or equivalent, in top of ball joint assembly. 5. Using suitable press, press ball joint assembly completely out of control arm. 6. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Replacement > Page 4986 Ball Joint: Service and Repair Upper Ball Joint Replacement 1. Remove lower control arm following procedure outlined under Control Arm/ Control Arm Replacement. 2. Using screwdriver or other suitable tool, pry ball joint seal boot off ball joint assembly. 3. Position receiving cup tool No. 6758, or equivalent, to support lower control arm while receiving ball joint assembly. 4. Install receiver/installer tool No. 6804, or equivalent, in top of ball joint assembly. 5. Using suitable press, press ball joint assembly completely out of control arm. 6. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration Control Arm Bushing: Customer Interest Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 4996 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 4997 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration Control Arm Bushing: All Technical Service Bulletins Steering/Suspension - Smooth Road Vibration NUMBER: 02-09-99 GROUP: Suspension DATE: July 2, 1999 SUBJECT: Smooth Road Steering Wheel Vibration OVERVIEW: This bulletin involves inspecting and correcting front suspension components and replacing the front suspension lower control arm rear bushing as needed. MODELS: 1995-1999 (PL) Neon SYMPTOM/CONDITION: A smooth road steering wheel back and forth oscillation/vibration may be observed when driving at around 72 MPH. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 5003 Test drive the vehicle on a smooth road with all accessories turned off to determine the speed and magnitude of the vibration/shake condition. PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: > 02-09-99 > Jul > 99 > Steering/Suspension - Smooth Road Vibration > Page 5004 2 05016581AA Bushing, Front Lower Control Arm Rear Isolator REPAIR PROCEDURE: 1. Remove and replace the front lower control arm rear isolator bushing following the procedure in the appropriate Neon Service Manual, Section 2, Suspension. 2. Set the wheel alignment using the procedures and the specifications found in the appropriate Neon Service Manual, Section 2, Suspension. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-10-06-90 2.9 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well - Creak/Rattle on Bumps Technical Service Bulletin # 23-47-97 Date: 970926 Front Foot Well - Creak/Rattle on Bumps NO: 23-47-97 GROUP: Body EFFECTIVE DATE: Sept. 26, 1997 SUBJECT: Creak/Rattle From Front Foot Well MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Creak/rattle from driver or passenger front foot well. The creak/rattle is more pronounced over bumps. DIAGNOSIS: Drive the vehicle over a bumpy road and listen for a creak/rattle in the foot well area. If creak/rattle is heard proceed with the repair procedure on the side that the noise is heard. If the side the creak/rattle is coming from cannot be determined by sound, torque each crossmember bolt to 163 Nm (120 ft lbs). If the bolt was at 163 Nm (120 ft.lbs), the torque is acceptable and no further action is needed on that side. If the torque was not at 163 Nm (120 ft. lbs), proceed to the Repair Procedure. PARTS REQUIRED: AR(1) 05011650AA Crossmember Bolt/Nut Repair Kit (Right) AR(1) 05011651AA Crossmember Bolt/Nut Repair Kit (Left) Each kit will include one of the following components: Cage Nut, Crossmember Bolt, Crossmember Mastic Patch Drain Plug Access Hole Template POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-30-01-90 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves drilling an access hole to replace the crossmember bolt and cage nut, then sealing the access hole. 1. Raise vehicle to gain access to the crossmember bolt. 2. Remove the crossmember bolt. 3. Lower the vehicle and open the door. 4. Slide the seat to the full rearward position. Remove the floor mat if so equipped. 5. Remove the scuff plate and kick panel. 6. Pull the carpet and pad away to access the floor. 7. Prop the clutch and brake pedal to make room for drilling (drivers side only). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well - Creak/Rattle on Bumps > Page 5013 8. Insert the template, mark and center punch the floor pan (Figure 1). 9. Using a drill and 70 mm (2-3/4") Dia hole saw, drill in the floor to access the cage nut. 10. Pry up on the cage surrounding the nut and slide the nut out. 11. Insert the new nut and bend the cage back into position to secure the nut. 12. Raise the vehicle and install the new bolt, torque to 163 Nm (120 ft. lbs.) 13. Lower the vehicle and vacuum all drill shavings. 14. Install the drain hole plug into the hole in the floor. Use a heat gun to seal the plug to the floor. 15. Center the mastic patch over the drain hole plug and install (Figure 2). To install, remove backing paper and apply firm even pressure across the entire patch to seal. 16. Position pad and carpet into proper location. 17. Remove prop holding brake and clutch pedal if applied. 18. Install the scuff plate and kick panel. 19. Install floor mat and reposition seat. 20. Repeat procedure for other side if needed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well Creak/Rattle on Bumps Technical Service Bulletin # 23-47-97 Date: 970926 Front Foot Well - Creak/Rattle on Bumps NO: 23-47-97 GROUP: Body EFFECTIVE DATE: Sept. 26, 1997 SUBJECT: Creak/Rattle From Front Foot Well MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Creak/rattle from driver or passenger front foot well. The creak/rattle is more pronounced over bumps. DIAGNOSIS: Drive the vehicle over a bumpy road and listen for a creak/rattle in the foot well area. If creak/rattle is heard proceed with the repair procedure on the side that the noise is heard. If the side the creak/rattle is coming from cannot be determined by sound, torque each crossmember bolt to 163 Nm (120 ft lbs). If the bolt was at 163 Nm (120 ft.lbs), the torque is acceptable and no further action is needed on that side. If the torque was not at 163 Nm (120 ft. lbs), proceed to the Repair Procedure. PARTS REQUIRED: AR(1) 05011650AA Crossmember Bolt/Nut Repair Kit (Right) AR(1) 05011651AA Crossmember Bolt/Nut Repair Kit (Left) Each kit will include one of the following components: Cage Nut, Crossmember Bolt, Crossmember Mastic Patch Drain Plug Access Hole Template POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-30-01-90 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves drilling an access hole to replace the crossmember bolt and cage nut, then sealing the access hole. 1. Raise vehicle to gain access to the crossmember bolt. 2. Remove the crossmember bolt. 3. Lower the vehicle and open the door. 4. Slide the seat to the full rearward position. Remove the floor mat if so equipped. 5. Remove the scuff plate and kick panel. 6. Pull the carpet and pad away to access the floor. 7. Prop the clutch and brake pedal to make room for drilling (drivers side only). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well Creak/Rattle on Bumps > Page 5019 8. Insert the template, mark and center punch the floor pan (Figure 1). 9. Using a drill and 70 mm (2-3/4") Dia hole saw, drill in the floor to access the cage nut. 10. Pry up on the cage surrounding the nut and slide the nut out. 11. Insert the new nut and bend the cage back into position to secure the nut. 12. Raise the vehicle and install the new bolt, torque to 163 Nm (120 ft. lbs.) 13. Lower the vehicle and vacuum all drill shavings. 14. Install the drain hole plug into the hole in the floor. Use a heat gun to seal the plug to the floor. 15. Center the mastic patch over the drain hole plug and install (Figure 2). To install, remove backing paper and apply firm even pressure across the entire patch to seal. 16. Position pad and carpet into proper location. 17. Remove prop holding brake and clutch pedal if applied. 18. Install the scuff plate and kick panel. 19. Install floor mat and reposition seat. 20. Repeat procedure for other side if needed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Customer Interest for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension Popping/Creaking Noises Front Steering Knuckle: Customer Interest Front Suspension - Popping/Creaking Noises NO: 02-02-97 Rev. A GROUP: Front Suspension EFFECTIVE DATE: Dec. 15, 1997 SUBJECT: Popping/Creaking Noise in Front Suspension THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-02-97 DATED FEBRUARY 28, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL FRONT SUSPENSION NOISE DIAGNOSTICS/REPAIRS HAVE BEEN ADDED. THE ADDITIONS ARE HIGHLIGHTED WITH ASTERISKS. MODELS: 1995 - 1998 (PL) Neon SYMPTOM/CONDITION: **A popping noise from the front suspension may be experienced while: ^ Going in reverse or forward with the steering wheel turned completely in one direction (parking lot maneuvers). ^ Shifting from drive to reverse, reverse to drive, etc. ^ Pulling in/out of driveway. ^ Large dips/bumps in the road such as speed bumps. ** DIAGNOSIS: If the customer describes the front suspension noise in conditions such as those described above, perform the Repair Procedure. PARTS REQUIRED: NOTE: THE 1995 NEONS BUILT IN 1994 USED 13" KNUCKLE ASSEMBLIES WITH 13" OR 14" WHEELS. LATER BUILT VEHICLES HAVE 13" OR 14" KNUCKLE ASSEMBLIES TO MATCH ORIGINAL WHEEL SIZE. TO DETERMINE THE PROPER KNUCKLE SIZE, COUNT THE STUDS ON THE HUB THEN REFER TO THE PARTS LIST PROVIDED IN THIS BULLETIN. CAUTION: DO NOT USE THE WHEEL SIZE TO DETERMINE PROPER KNUCKLE PART NUMBERS. REPAIR PROCEDURE: **This bulletin involves inspecting/replacing as needed both front wheel bearings and steering knuckles, front upper strut mounts, engine mounts, and lubing the driveshafts.** Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Customer Interest for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension Popping/Creaking Noises > Page 5028 **NOTE: USE TABLE TO DETERMINE WHICH STEPS TO PERFORM BASED ON VEHICLE BUILD DATE AND IF TECHNICAL SERVICE BULLETIN 02-02-97, DATED FEBRUARY 28, 1997 HAS BEEN PERFORMED.** NOTE: ALL FRONT KNUCKLE/BEARING/HUB REPAIR PROCEDURES FOR STEPS 1 THROUGH 5, CAN BE FOUND IN THE 1998 NEON SERVICE MANUAL (PUBLICATION NUMBER 81-270-8025) GROUP 2 (SUSPENSION). 1. Remove both left and right front knuckle/bearing/hub assemblies. 2. Press the hub out of the old knuckle/bearing/hub assemblies. 3. Press the old hubs into the new knuckle/bearing assemblies. **4. Before the knuckle/bearing/hub assemblies are installed on the vehicle, put a small amount of grease (Wheel Bearing Lube - p/n 04318064) on the entire face of the driveshaft that makes contact with the hub bearing assembly (Figure 1).** 5. Install both left and right front knuckle/bearing/hub assemblies. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Customer Interest for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension Popping/Creaking Noises > Page 5029 **6. Replace the upper strut mount by following the procedures in the 1998 Neon Service Manual (Publication No. 81-270-8025), Removal/Installation, pages 2-16 to 2-17, and Assembly/Disassembly procedures 1 thru 5 on pages 2-30 to 2-31 (Figure 2). The torque for the new upper strut mount nuts is 61 Nm (45 ft.lbs).** **7. Remove and replace the right engine mount as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) (SOHC - pg 9-18)(DOHC - pg 9-64). After replacing the right engine mount, squirt enough grease (Silicone Spray - p/n 04318070) between the mount snubber and the engine bracket to fill the gap (Figure 3).** NOTE: IF THE SILICONE SPRAY (P/N 04318070) IS NOT AVAILABLE, ANOTHER SILICONE SPRAY MAY BE USED. HOWEVER THE SUBSTITUTE SILICONE SPRAY MUST NOT BE PETROLEUM BASED. **8. Inspect and tighten remaining suspension components to specification; repair or replace as needed.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-05-30-93 Knuckles and Mounts - Replace - All 2.9 Hrs. 02-05-39-91 Upper Strut Mounts and Engine Mount - Replace 1.3 Hrs. 09-40-21-91 Engine Mount Replace 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension - Popping/Creaking Noises Front Steering Knuckle: All Technical Service Bulletins Front Suspension - Popping/Creaking Noises NO: 02-02-97 Rev. A GROUP: Front Suspension EFFECTIVE DATE: Dec. 15, 1997 SUBJECT: Popping/Creaking Noise in Front Suspension THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-02-97 DATED FEBRUARY 28, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL FRONT SUSPENSION NOISE DIAGNOSTICS/REPAIRS HAVE BEEN ADDED. THE ADDITIONS ARE HIGHLIGHTED WITH ASTERISKS. MODELS: 1995 - 1998 (PL) Neon SYMPTOM/CONDITION: **A popping noise from the front suspension may be experienced while: ^ Going in reverse or forward with the steering wheel turned completely in one direction (parking lot maneuvers). ^ Shifting from drive to reverse, reverse to drive, etc. ^ Pulling in/out of driveway. ^ Large dips/bumps in the road such as speed bumps. ** DIAGNOSIS: If the customer describes the front suspension noise in conditions such as those described above, perform the Repair Procedure. PARTS REQUIRED: NOTE: THE 1995 NEONS BUILT IN 1994 USED 13" KNUCKLE ASSEMBLIES WITH 13" OR 14" WHEELS. LATER BUILT VEHICLES HAVE 13" OR 14" KNUCKLE ASSEMBLIES TO MATCH ORIGINAL WHEEL SIZE. TO DETERMINE THE PROPER KNUCKLE SIZE, COUNT THE STUDS ON THE HUB THEN REFER TO THE PARTS LIST PROVIDED IN THIS BULLETIN. CAUTION: DO NOT USE THE WHEEL SIZE TO DETERMINE PROPER KNUCKLE PART NUMBERS. REPAIR PROCEDURE: **This bulletin involves inspecting/replacing as needed both front wheel bearings and steering knuckles, front upper strut mounts, engine mounts, and lubing the driveshafts.** Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension - Popping/Creaking Noises > Page 5035 **NOTE: USE TABLE TO DETERMINE WHICH STEPS TO PERFORM BASED ON VEHICLE BUILD DATE AND IF TECHNICAL SERVICE BULLETIN 02-02-97, DATED FEBRUARY 28, 1997 HAS BEEN PERFORMED.** NOTE: ALL FRONT KNUCKLE/BEARING/HUB REPAIR PROCEDURES FOR STEPS 1 THROUGH 5, CAN BE FOUND IN THE 1998 NEON SERVICE MANUAL (PUBLICATION NUMBER 81-270-8025) GROUP 2 (SUSPENSION). 1. Remove both left and right front knuckle/bearing/hub assemblies. 2. Press the hub out of the old knuckle/bearing/hub assemblies. 3. Press the old hubs into the new knuckle/bearing assemblies. **4. Before the knuckle/bearing/hub assemblies are installed on the vehicle, put a small amount of grease (Wheel Bearing Lube - p/n 04318064) on the entire face of the driveshaft that makes contact with the hub bearing assembly (Figure 1).** 5. Install both left and right front knuckle/bearing/hub assemblies. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Steering Knuckle: > 02-02-97A > Dec > 97 > Front Suspension - Popping/Creaking Noises > Page 5036 **6. Replace the upper strut mount by following the procedures in the 1998 Neon Service Manual (Publication No. 81-270-8025), Removal/Installation, pages 2-16 to 2-17, and Assembly/Disassembly procedures 1 thru 5 on pages 2-30 to 2-31 (Figure 2). The torque for the new upper strut mount nuts is 61 Nm (45 ft.lbs).** **7. Remove and replace the right engine mount as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) (SOHC - pg 9-18)(DOHC - pg 9-64). After replacing the right engine mount, squirt enough grease (Silicone Spray - p/n 04318070) between the mount snubber and the engine bracket to fill the gap (Figure 3).** NOTE: IF THE SILICONE SPRAY (P/N 04318070) IS NOT AVAILABLE, ANOTHER SILICONE SPRAY MAY BE USED. HOWEVER THE SUBSTITUTE SILICONE SPRAY MUST NOT BE PETROLEUM BASED. **8. Inspect and tighten remaining suspension components to specification; repair or replace as needed.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-05-30-93 Knuckles and Mounts - Replace - All 2.9 Hrs. 02-05-39-91 Upper Strut Mounts and Engine Mount - Replace 1.3 Hrs. 09-40-21-91 Engine Mount Replace 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 5037 Front Steering Knuckle: Service and Repair 1. Remove cotter pin, castle nut and hub nut while vehicle is still on floor with brakes applied. 2. Raise and support vehicle, then remove front tire and wheel assembly. 3. Remove front disc brake caliper and place aside. CAUTION: Do not let caliper assembly hang by hose. 4. Remove front disc brake, then disconnect tie rod from steering knuckle using removal tool No. MB-990635, or equivalent. 5. Separate ball joint stud from steering knuckle by prying down on lower control arm. Ensure ball joint seal is not damage. 6. Pull steering knuckle assembly out and away from outer CV joint of driveshaft assembly. 7. Remove two steering knuckle to strut damper attaching bolts, then the steering knuckle and hub/bearing assembly from vehicle. 8. Reverse procedure to install. Torque clamp bolt to 70 ft.-lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair Lateral Stabilizer Rod: Service and Repair Rear suspension lateral link bushings are not replaceable. Lateral links are serviced as a unit. The lateral links are not interchangeable. The forward link is non adjustable, both bushings sleeves are the same size. The rearward link is adjustable, the small bushing sleeve must be placed at the spindle knuckle to allow toe adjustments. 1. Raise and support vehicle, then remove rear wheels. 2. Remove lateral link attachment bolt and washers at the spindle knuckle. 3. Remove lateral link attachment bolt, washers and adjustment cams at the cross member, then remove lateral links. 4. Reverse procedure to install, noting the following: a. Tighten nuts and bolts to specifications. b. Forward lateral links have same size bushing sleeves at each end. c. Rearward lateral links have two different size bushing sleeves, small bushing sleeve must be installed at spindle knuckle end. d. The short mounting bolt is used at the spindle knuckle end, and must be installed with head of bolt towards front of vehicle. e. The long mounting bolt is used at the crossmember end, and must be installed with head of bolt towards rear of vehicle. f. Lateral link bolts must be tightened to specification with suspension supporting vehicle weight. g. Check and adjust rear wheel alignment as outlined under Wheel Alignment. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > With Rear Drum Brakes Rear Knuckle: Service and Repair With Rear Drum Brakes 1. Remove rear hub and bearing as outlined under Transmission and Drivetrain/ Drive Axles, Bearings and Joints/ Rear Hub & Bearing Replacement. ABS Speed Sensor Location. Rear Drum Brakes ABS Speed Sensor Location. Rear Disc Brakes 2. On models equipped with ABS, remove the retaining bolt, then the speed sensor. If speed sensor is seized, do not use pliers to remove. Gently tap on mounting ear with a suitable punch and hammer to loosen sensor. 3. Remove brake support plate mounting bolts, then without disconnecting brake fluid hose, position and support assembly aside. CAUTION: Do not allow assembly to hang from the brake fluid hose. 4. Loosen but do not remove spindle knuckle to strut clevis nuts. The spindle knuckle to strut clevis bolts are serrated for a tight fit into the knuckle. NOTE: Do not turn bolt when loosening. Turn nut only, or damage to knuckle or bolt will occur. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > With Rear Drum Brakes > Page 5045 Tension Strut Removal 5. Remove lateral link to knuckle bolt, then using a suitable adjustable wrench to prevent tension strut from turning, remove tension strut nut, washer and bushing. 6. Remove spindle knuckle to strut clevis bolts that were previously loosened, then pull spindle knuckle straight out of strut and rotate off tension strut. 7. Reverse procedure to install, noting the following: a. Tighten bolts and nuts to specifications. b. When tightening spindle knuckle to strut clevis bolts, do not turn bolts. Tighten by turning nuts only. c. The lateral link to spindle knuckle bolt must be installed with head of bolt towards front of vehicle. d. Lateral link bolts must be tightened to specifications with suspension supporting vehicle weight. Tension Strut Bushings f. Check and adjust rear wheel alignment as outlined under Steering and Suspension / Alignment / Adjustments. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > With Rear Drum Brakes > Page 5046 Rear Knuckle: Service and Repair With Rear Disc Brakes 1. Remove rear hub and bearing as outlined under Transmission and Drivetrain/ Drive Axles, Bearings and Joints/ Rear Hub & Bearing Replacement. ABS Speed Sensor Location. Rear Drum Brakes ABS Speed Sensor Location. Rear Disc Brakes 2. On models equipped with ABS, remove the retaining bolt, then the speed sensor. If speed sensor is seized, do not use pliers to remove. Gently tap on mounting ear with a suitable punch and hammer to loosen sensor. 3. Remove disc brake adapter plate mounting bolts, then without disconnecting brake fluid hose, position and support assembly aside. CAUTION: Do not allow assembly to hang from the brake fluid hose. 4. Loosen but do not remove spindle knuckle to strut clevis nuts. The spindle knuckle to strut clevis bolts are serrated for a tight fit into the knuckle. CAUTION: Do not turn bolt when loosening. Turn nut only, or damage to knuckle or bolt will occur. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > With Rear Drum Brakes > Page 5047 Tension Strut Removal 5. Remove lateral link to knuckle bolt, then using a suitable adjustable wrench to prevent tension strut from turning, remove tension strut nut, washer and bushing. 6. Remove spindle knuckle to strut clevis bolts that were previously loosened, then pull spindle knuckle straight out of strut and rotate off tension strut. 7. Reverse procedure to install, noting the following: a. Tighten bolts and nuts to specifications. b. When tightening spindle knuckle to strut clevis bolts, do not turn bolts. Tighten by turning nuts only. c. The lateral link to spindle knuckle bolt must be installed with head of bolt towards front of vehicle. d. Lateral link bolts must be tightened to specifications with suspension supporting vehicle weight. Tension Strut Bushings f. Check and adjust rear wheel alignment as outlined under Steering and Suspension / Alignment / Adjustments. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > With Rear Drum Brakes Spindle: Service and Repair With Rear Drum Brakes 1. Remove rear hub and bearing as outlined under Transmission and Drivetrain/ Drive Axles, Bearings and Joints/ Rear Hub & Bearing Replacement. ABS Speed Sensor Location. Rear Drum Brakes ABS Speed Sensor Location. Rear Disc Brakes 2. On models equipped with ABS, remove the retaining bolt, then the speed sensor. If speed sensor is seized, do not use pliers to remove. Gently tap on mounting ear with a suitable punch and hammer to loosen sensor. 3. Remove brake support plate mounting bolts, then without disconnecting brake fluid hose, position and support assembly aside. Do not allow assembly to hang from the brake fluid hose. 4. Loosen but do not remove spindle knuckle to strut clevis nuts. The spindle knuckle to strut clevis bolts are serrated for a tight fit into the knuckle. Do not turn bolt when loosening. Turn nut only, or damage to knuckle or bolt will occur. Tension Strut Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > With Rear Drum Brakes > Page 5052 5. Remove lateral link to knuckle bolt, then using a suitable adjustable wrench to prevent tension strut from turning, remove tension strut nut, washer and bushing. 6. Remove spindle knuckle to strut clevis bolts that were previously loosened, then pull spindle knuckle straight out of strut and rotate off tension strut. 7. Reverse procedure to install, noting the following: a. Tighten bolts and nuts to specifications. b. When tightening spindle knuckle to strut clevis bolts, do not turn bolts. Tighten by turning nuts only. c. The lateral link to spindle knuckle bolt must be installed with head of bolt towards front of vehicle. d. Lateral link bolts must be tightened to specifications with suspension supporting vehicle weight. Tension Strut Bushings e. Refer to image when installing tension strut retainer washers and bushings. f. Check and adjust rear wheel alignment as outlined under Steering and Suspension / Alignment / Adjustments. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > With Rear Drum Brakes > Page 5053 Spindle: Service and Repair With Rear Disc Brakes 1. Remove rear hub and bearing as outlined under Transmission and Drivetrain/ Drive Axles, Bearings and Joints/ Rear Hub & Bearing Replacement. ABS Speed Sensor Location. Rear Drum Brakes ABS Speed Sensor Location. Rear Disc Brakes 2. On models equipped with ABS, remove the retaining bolt, then the speed sensor. If speed sensor is seized, do not use pliers to remove. Gently tap on mounting ear with a suitable punch and hammer to loosen sensor. 3. Remove disc brake adapter plate mounting bolts, then without disconnecting brake fluid hose, position and support assembly aside. Do not allow assembly to hang from the brake fluid hose. 4. On all models, loosen but do not remove spindle knuckle to strut clevis nuts. The spindle knuckle to strut clevis bolts are serrated for a tight fit into the knuckle. Do not turn bolt when loosening. Turn nut only, or damage to knuckle or bolt will occur. Tension Strut Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > With Rear Drum Brakes > Page 5054 5. Remove lateral link to knuckle bolt, then using a suitable adjustable wrench to prevent tension strut from turning, remove tension strut nut, washer and bushing. 6. Remove spindle knuckle to strut clevis bolts that were previously loosened, then pull spindle knuckle straight out of strut and rotate off tension strut. 7. Reverse procedure to install, noting the following: a. Tighten bolts and nuts to specifications. b. When tightening spindle knuckle to strut clevis bolts, do not turn bolts. Tighten by turning nuts only. c. The lateral link to spindle knuckle bolt must be installed with head of bolt towards front of vehicle. d. Lateral link bolts must be tightened to specifications with suspension supporting vehicle weight. Tension Strut Bushings e. Refer to image when installing tension strut retainer washers and bushings. f. Check and adjust rear wheel alignment as outlined under Steering and Suspension / Alignment / Adjustments. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair Stabilizer Bar: Service and Repair 1. Raise and support vehicle, then remove both rear wheels. 2. Disconnect roll bar from attaching links at each side, then swing bar down to clear links. 3. Remove bolts from roll bar attaching brackets, then remove roll bar from vehicle. 4. Reverse procedure to install, noting the following: a. Tighten nuts and bolts to specifications. b. Ensure slit in roll bar bushings face rear of vehicle when installed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-06-98A > Jun > 98 > Front Suspension - Popping Noise On Bumps Suspension Spring ( Coil / Leaf ): Customer Interest Front Suspension - Popping Noise On Bumps NO.: 02-06-95 Rev. A GROUP: Suspension DATE: Jun. 19, 1998 THIS BULLETIN SUPERCEDES TECHNICAL SERVICE BULLETINS 02-01-98 DATED MARCH 27, 1998 AND 02-06-98 DATED JUNE 5, 1998. BOTH BULLETINS SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE SYMPTOM/CONDITION AND THE DIAGNOSTIC PROCEDURE HAVE BEEN REVISED. MODELS: 1995 - 1998 (PL) Neon SYMPTOM/CONDITION: **A popping noise from the front end while traveling over bumps with wheels straight or when turning. ** The popping noise may be more apparent when suspension is wet, such as in a heavy rain. DIAGNOSIS: **Wet the front coil springs and surrounding suspension components with a light spray from a garden hose. Immediately drive the vehicle over a small bump (such as a speed bump) while making a turn. If a popping noise is heard, perform the Repair Procedure. ** PARTS REQUIRED: 2 05273399 Spring Sleeve, Front Coil Springs REPAIR PROCEDURE: This bulletin involves the addition of a spring sleeve to each front coil spring. 1. Remove the strut assembly as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) on page 2-15. 2. Disassemble the strut assembly as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) on page 2-30. 3. Clean the mating surface of the spring and strut spring seat. If surface rust is present, use a smooth scuff pad to remove the rust. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-06-98A > Jun > 98 > Front Suspension - Popping Noise On Bumps > Page 5066 NOTE: THE EFFECTED AREA WILL SHOW SIGNS OF RUST OR PAINT WEAR. THIS IS THE AREA THAT SHOULD BE COVERED BY THE SPRING SLEEVE. 4. Apply the spring sleeve (p/n 5273399) to the spring. The spring sleeve should be positioned onto the spring to cover the effected area (Figure 1). 5. Assemble the strut assembly following the procedure in the 1995 Neon Service Manual (Publication No. 81-270-8025) beginning on page 2-32. 6. Install the strut assembly into the vehicle following the procedure in the 1998 Neon Service Manual (Publication No. 81-270-8025) beginning on page 2-16. 7. Repeat the procedure for the other side. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-27-01-92 1.0 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-06-98A > Jun > 98 > Front Suspension - Popping Noise On Bumps Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Front Suspension - Popping Noise On Bumps NO.: 02-06-95 Rev. A GROUP: Suspension DATE: Jun. 19, 1998 THIS BULLETIN SUPERCEDES TECHNICAL SERVICE BULLETINS 02-01-98 DATED MARCH 27, 1998 AND 02-06-98 DATED JUNE 5, 1998. BOTH BULLETINS SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE SYMPTOM/CONDITION AND THE DIAGNOSTIC PROCEDURE HAVE BEEN REVISED. MODELS: 1995 - 1998 (PL) Neon SYMPTOM/CONDITION: **A popping noise from the front end while traveling over bumps with wheels straight or when turning. ** The popping noise may be more apparent when suspension is wet, such as in a heavy rain. DIAGNOSIS: **Wet the front coil springs and surrounding suspension components with a light spray from a garden hose. Immediately drive the vehicle over a small bump (such as a speed bump) while making a turn. If a popping noise is heard, perform the Repair Procedure. ** PARTS REQUIRED: 2 05273399 Spring Sleeve, Front Coil Springs REPAIR PROCEDURE: This bulletin involves the addition of a spring sleeve to each front coil spring. 1. Remove the strut assembly as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) on page 2-15. 2. Disassemble the strut assembly as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) on page 2-30. 3. Clean the mating surface of the spring and strut spring seat. If surface rust is present, use a smooth scuff pad to remove the rust. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-06-98A > Jun > 98 > Front Suspension - Popping Noise On Bumps > Page 5072 NOTE: THE EFFECTED AREA WILL SHOW SIGNS OF RUST OR PAINT WEAR. THIS IS THE AREA THAT SHOULD BE COVERED BY THE SPRING SLEEVE. 4. Apply the spring sleeve (p/n 5273399) to the spring. The spring sleeve should be positioned onto the spring to cover the effected area (Figure 1). 5. Assemble the strut assembly following the procedure in the 1995 Neon Service Manual (Publication No. 81-270-8025) beginning on page 2-32. 6. Install the strut assembly into the vehicle following the procedure in the 1998 Neon Service Manual (Publication No. 81-270-8025) beginning on page 2-16. 7. Repeat the procedure for the other side. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-27-01-92 1.0 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Alignment & Suspension - Specifications & Adjustment Suspension Strut / Shock Absorber: Technical Service Bulletins Alignment & Suspension Specifications & Adjustment NO: 02-04-97 GROUP: Suspension DATE: May 16, 1997 SUBJECT: Front End Alignment Torque Specifications & Shock Adjustment Procedures On Competition Package MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH THE COMPETITION PACKAGE SALES CODE (ACR) SUSPENSION SALES CODE (SDK). DISCUSSION: The alignment on ACR equipped vehicles must be set to the preferred specifications provided in the 1997 Neon Service Manual (Publication Number 81-270-7025) page 2-7. After each final setting the nuts should then be torqued to 75 ft.lbs plus an additional 90 degree turn. It is important that the proper torque be used to maintain the proper alignment. If the alignment is outside of specifications, rapid and excessive tire wear will result. Starting in 1997, Neon competition package (ACR) vehicles come equipped with adjustable strut dampers on all four wheels. The struts are finely tuned to the ride and handling profile of the entire suspension system. If the customer wishes to change the dampening force for special conditions the dampening characteristics of the strut dampers are adjustable on the ACR equipped vehicles. The knob for adjusting the strut can be found in a packet located in the glove compartment. The adjustment procedures are as follows: 1. The top end of the adjusting rod has flats over which the adjusting knob will fit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Alignment & Suspension - Specifications & Adjustment > Page 5077 2. Install the knob over the top end of the front or rear damper and lock it into position by turning counterclockwise slowly until the knob engages, (Illustration). 3. Turn the adjusting knob clockwise, if resistance is felt do not use force, as the damper is in an unadjusted position. Reverse the adjustment slightly and try again. When the damper is in the full clockwise position, this is the minimum (City Ride) position. 4. To adjust the dampening force, the adjusting knobs has to be turned in the direction of the arrow for increased dampening and the opposite direction for decreased dampening. NOTE: BOTH THE LEFT AND RIGHT STRUT DAMPERS MUST BE ADJUSTED IDENTICALLY. FAILURE TO DO SO COULD PRODUCE UNSTABLE HANDLING AND UNEVEN TIRE TREAD WEAR. 5. The following is a description of the various settings and the adjustment procedure. A. City Ride - To enjoy the most comfortable city ride, the struts should be left in the "minimum" position as they are set from the assembly plant. To set to minimum the knob should be turned completely clockwise. B. Cross Country - The cross country setting will give the car a firmer handling characteristic, but yet will still be very comfortable to drive. To set, turn the adjusting knob 1/2 turn counter clockwise from the "minimum" position. C. G.T./Aggressive Driving - This setting equates the car's handling to a cross-country grand turismo car, offering increased cornering ability, improved road feel and precise directional stability at higher speeds. To set turn the adjusting knob 1 turn counter clockwise from the "minimum" position. 6. Remove the adjusting knob before closing the hood or trunk. The vehicle should not be driven with the adjusting knob in place. NOTE: DURING INSPECTION/SERVICING A THIN FILM OF OIL AND DUST COLLECTION MAY BE NOTICED ON THE OUTSIDE OF THE STRUT TUBE. THIS IS A NORMAL CONDITION WHICH OCCURS DURING THE DAMPER INTERNAL SEAL "BREAK-IN" PERIOD AND DOES NOT AFFECT THE PERFORMANCE OF THE STRUT AND DOES NOT INDICATE THE NEED FOR STRUT REPLACEMENT. STRUT REPLACEMENT SHOULD ONLY OCCUR IF THE STRUT LEAKAGE IS SUFFICIENT TO COVER THE ENTIRE STRUT DAMPER TUBE AND HAS "DRIPPED" ONTO THE LOWER CONTROL ARM OR ONTO THE PAVEMENT DURING OVERNIGHT PARKING. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 Disassembly/Assembly 1. Clamp strut assembly by the clevis bracket into suitable vise. Coil Spring Removal 2. Scribe coil spring and strut assembly right or left, then using compressor tool No. C-4838, or equivalent, compress coil spring. 3. Install socket strut nut tool No. L4558A, or equivalent, on strut shaft retaining nut. 4. Install 10 mm socket on hex head of strut shaft and remove nut while holding strut to keep from rotating. 5. Remove upper spring seat, pivot bearing and dust shield as an assembly. 6. Remove coil spring. 7. Reverse procedure to install. With ABS 1. Loosen wheel lug nuts, then raise and support vehicle. 2. Remove wheel and tire assembly, then disconnect the hydraulic brake hose routing bracket from strut bracket. 3. Speed sensor is combined with hydraulic hose routing bracket. 4. Remove two strut assembly clevis bracket to steering knuckle attaching bolts. 5. Remove three nuts attaching strut assembly upper mount to shock tower, then the strut. 6. Reverse procedure to install. Without ABS 1. Loosen wheel lug nuts, then raise and support vehicle. 2. Remove wheel and tire assembly, then disconnect the hydraulic brake hose routing bracket from strut bracket. 3. Remove two strut assembly clevis bracket to steering knuckle attaching bolts. 4. Remove three nuts attaching strut assembly upper mount to shock tower, then the strut. 5. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 5080 Suspension Strut / Shock Absorber: Service and Repair Rear Replacement 1. Raise and support vehicle, then remove wheel. 2. Remove brake fluid hose support bracket from strut. 3. On models equipped with ABS, remove speed sensor cable and routing clip from strut. 4. On all models, Loosen but do not remove spindle knuckle to strut clevis bolts. The spindle knuckle to strut clevis bolts are serrated for a tight fit into the knuckle. CAUTION: Do not turn bolt when loosening. Turn nut only, or damage to knuckle or bolt will occur. 5. Lower vehicle, then access four upper strut to strut tower mounting nuts. Removing carpeting and dust shield as necessary. 6. Loosen but do not remove upper strut to tower mounting nuts. 7. Using a suitable device, support suspension. CAUTION: Do not allow suspension components to hang after removing strut. Do not place support under lateral links or tension strut as they may bend. 8. Remove previously loosened upper strut mounting nuts and strut to spindle knuckle bolts. 9. Slide strut straight back off spindle knuckle, then lower strut from vehicle. 10. Reverse procedure to install, noting the following: a. Tighten bolts and nuts to specifications. b. When tightening spindle knuckle to strut clevis bolts, do not turn bolts, tighten by turning nuts only. c. Check and adjust rear wheel alignment as outlined under Wheels, Suspension/ Tires and Alignment/ Wheel/ Wheel Alignment. Strut Service Coil springs on this vehicle are available in different load rates. Spring rates may be different on each side of the vehicle depending on how the vehicle is equipped. Ensure correct spring rates are chosen during assembly. The gas-charged strut damper cannot be rebuilt and is serviced as a unit. 1. Remove strut assembly as outlined under Strut Replacement. 2. Using a suitable marker or paint, place match marks on components of strut assembly to aid in assembly alignment. Strut Assembly Mounted In Vise 3. Place strut assembly into a suitable vise. CAUTION: Do not clamp body of strut into vise. 4. Using coil spring compressor tool No. C-4838, or equivalent, compress spring until tension is removed from upper strut mount assembly. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 5081 Strut Shaft Nut Replacement 5. Using strut nut wrench tool No. L-4558A, or equivalent, and a 10 mm socket and breaker bar to hold strut shaft, remove strut shaft nut. Fig. 1 Exploded View Of Rear Suspension 6. Remove outer washer, upper strut mount, coil spring, inner washer, dust shield, jounce bumper and spring isolator from strut. 7. Reverse procedure to install, noting the following: a. Tighten nuts to specifications. b. Install inner strut shaft washer with raised edge up and outer strut shaft washer with raised edge down. c. Transfer alignment marks to any replaced component. Ensure alignment of all components during assembly. Tension Strut Replacement 1. Using a suitable wrench to prevent tension strut from turning, remove nuts from both ends of tension strut. 2. Remove bushings and washers from tension strut, then remove tension strut. 3. Reverse procedure to install, noting the following: a. Tighten nuts to specifications. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 5082 Tension Strut Bushings b. Install tension strut bushings and washers. c. Check and adjust rear wheel alignment as outlined under Wheel Alignment. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front DISASSEMBLE All steps of the hub bearing removal from steering knuckle must be done using a hydraulic arbor press. 1. Install bearing splitter tool No. P334, or equivalent, on steering knuckle and hub/bearing assembly to support steering knuckle when pressing out bearing. Hub, Bearing & Steering Knuckle Supported For Removal Of Hub 2. Position steering knuckle and hub/bearing assembly in vise, support by splitter tool No. P334, or equivalent. 3. Position driver tool No. 6644-2, or equivalent, on small end of hub, then press hub from bearing. The one bearing race may come out with hub when hub is removed from bearing. Hub Bearing Removal 4. Remove bearing splitter from steering knuckle, then place steering knuckle is press supported by press blocks. 5. Place bearing driver tool No. MB-990799, or equivalent, on outer race of hub bearing, then press hub bearing completely out of steering knuckle. 6. Install bearing splitter tool No. P334, or equivalent, on hub so it is between flange of hub and bearing race remaining on hub. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5087 Hub Bearing Race Removal 7. Install assembly into press, then place driver tool on end of hub and press hub out of hub bearing race. ASSEMBLE 1. Install new bearing into bore of steering knuckle so it is square with bore, then place steering knuckle in press with receiver tool No. C-4698-2, or equivalent, supporting steering knuckle. 2. Place driver tool No. 5052, or equivalent, on outer race of hub, then press hub bearing into steering knuckle until it is fully bottom in bearing bore of steering knuckle. 3. Install hub bearing retaining snap ring into groove in hub bearing bore of steering knuckle. Ensure snap ring is fully seated. Hub Bearing Installation 4. Place steering knuckle with hub bearing installed in press with receiver tool No. MB-990799, or equivalent, supporting inner race of hub bearing. 5. Place hub into hub bearing ensuring it is square with bearing. 6. Place driver tool No. 6522, or equivalent, on front face of hub, then press hub into bearing until it bottoms in hub bearing. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 5088 Wheel Bearing: Service and Repair Rear With Rear Disc Brakes The rear hub and bearing are serviced as an assembly. 1. Raise and support vehicle, then remove wheel. 2. Remove caliper and disc. 3. Remove the hub retaining nut, then the hub and bearing assembly. 4. Reverse procedure to install. Tighten nuts and bolts to specifications. With Rear Drum Brakes The rear hub and bearing are serviced as an assembly. 1. Raise and support vehicle, then remove wheel. 2. Remove drum. 3. Remove the hub retaining nut, then the hub and bearing assembly. 4. Reverse procedure to install. Tighten nuts and bolts to specifications. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 5098 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 5104 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 5105 Axle Nut: Specifications Front Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 183 Nm (135 ft. lbs.) Rear Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 217 Nm (160 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire & Wheel - Runout Tires: Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Tire & Wheel - Runout Wheels: Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front DISASSEMBLE All steps of the hub bearing removal from steering knuckle must be done using a hydraulic arbor press. 1. Install bearing splitter tool No. P334, or equivalent, on steering knuckle and hub/bearing assembly to support steering knuckle when pressing out bearing. Hub, Bearing & Steering Knuckle Supported For Removal Of Hub 2. Position steering knuckle and hub/bearing assembly in vise, support by splitter tool No. P334, or equivalent. 3. Position driver tool No. 6644-2, or equivalent, on small end of hub, then press hub from bearing. The one bearing race may come out with hub when hub is removed from bearing. Hub Bearing Removal 4. Remove bearing splitter from steering knuckle, then place steering knuckle is press supported by press blocks. 5. Place bearing driver tool No. MB-990799, or equivalent, on outer race of hub bearing, then press hub bearing completely out of steering knuckle. 6. Install bearing splitter tool No. P334, or equivalent, on hub so it is between flange of hub and bearing race remaining on hub. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5119 Hub Bearing Race Removal 7. Install assembly into press, then place driver tool on end of hub and press hub out of hub bearing race. ASSEMBLE 1. Install new bearing into bore of steering knuckle so it is square with bore, then place steering knuckle in press with receiver tool No. C-4698-2, or equivalent, supporting steering knuckle. 2. Place driver tool No. 5052, or equivalent, on outer race of hub, then press hub bearing into steering knuckle until it is fully bottom in bearing bore of steering knuckle. 3. Install hub bearing retaining snap ring into groove in hub bearing bore of steering knuckle. Ensure snap ring is fully seated. Hub Bearing Installation 4. Place steering knuckle with hub bearing installed in press with receiver tool No. MB-990799, or equivalent, supporting inner race of hub bearing. 5. Place hub into hub bearing ensuring it is square with bearing. 6. Place driver tool No. 6522, or equivalent, on front face of hub, then press hub into bearing until it bottoms in hub bearing. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 5120 Wheel Bearing: Service and Repair Rear With Rear Disc Brakes The rear hub and bearing are serviced as an assembly. 1. Raise and support vehicle, then remove wheel. 2. Remove caliper and disc. 3. Remove the hub retaining nut, then the hub and bearing assembly. 4. Reverse procedure to install. Tighten nuts and bolts to specifications. With Rear Drum Brakes The rear hub and bearing are serviced as an assembly. 1. Raise and support vehicle, then remove wheel. 2. Remove drum. 3. Remove the hub retaining nut, then the hub and bearing assembly. 4. Reverse procedure to install. Tighten nuts and bolts to specifications. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Customer Interest for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 5130 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop Technical Service Bulletin # 05-01-98 Date: 980130 Rear Brakes - Howl During Low Speed Stop NO: 05-01-98 GROUP: Brakes DATE: Jan. 30, 1998 SUBJECT: Howl From Rear Brakes During Low Speed Stop THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-08-97 DATED NOVEMBER 7, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SALES CODES FOR COVERED VEHICLES HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995-1997 (PL) Neon **NOTE: THIS BULLETIN APPLIES TO ALL NON ABS EQUIPPED VEHICLES (SALES CODES BRA AND BRC). VEHICLES EQUIPPED WITH ABS DID NOT HAVE DRUM BRAKES.** SYMPTOM/CONDITION: A howl type noise coming from the rear brakes during a low speed (10 mph or less) brake apply in a forward direction. The condition may be more frequent in cold/damp weather during the first few stops with cold brakes. DIAGNOSIS: While traveling at 10 mph, lightly apply the brakes and listen for a low pitched howl from the rear. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011628AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Right) 1 05011629AA Brake Shoe Support Plate, Rear With Wheel Cylinder (Left) 2 04509544 Gasket, Brake Shoe Support Plate 2 06502432 Retaining Nut, Hub and Bearing Assembly POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-92 1.2 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the rear brake shoe support plate with a new brake shoe support plate. Attached to the new plate will be the wheel cylinder assembly and a damper weight. 1. Raise the vehicle on jack stands or centered on a frame contact type hoist. 2. Remove rear wheel and tire assembly. 3. Remove the brake drum. 4. Remove the dust cap from the rear hub/bearing. 5. Remove the retaining nut holding the rear hub/bearing to the spindle. Remove the hub/bearing from the spindle. 6. Remove the rear brake shoes from the brake support plate. 7. Disconnect the rear brake flex hose tube from the wheel cylinder. 8. Remove park brake actuator lever from the park brake cable. 9. Position a 1/2 in. wrench over the retainer fingers on the end of the parking brake cable. Compress cable housing retaining fingers and start cable Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > 05-01-98 > Jan > 98 > Rear Brakes - Howl During Low Speed Stop > Page 5136 housing out of support plate. Remove the wrench when retainer is free from the park brake cable mounting hole in the rear of the brake shoe support plate. 10. Remove the four brake support plate to knuckle attaching bolt and washer assemblies. Separate the brake shoe support plate from the rear suspension knuckle. 11. Transfer all brake hardware to the new backing plate. NOTE: THE NEW BRAKE SHOE SUPPORT PLATE COMES WITH THE WHEEL CYLINDER ATTACHED. THE WHEEL CYLINDER ATTACHING BOLTS SHOULD NOT BE LOOSENED OR REMOVED, AS THE POSITIONING OF THE REAR WHEEL CYLINDER IS CRITICAL. 12. Install the brake support plate and gasket on the rear suspension knuckle casting. Torque the support plate to knuckle casting bolts to 75 Nm (55 ft. lbs.). 13. Insert parking brake cable end fitting into brake support plate. 14. Hand start the hydraulic brake hose tube fitting to wheel cylinder. Torque tube nut to wheel cylinder fitting to 17 Nm (145 in. lbs.) 15. Attach parking brake cable to the parking brake actuator. 16. Install the rear brake shoe assemblies on the brake support plate. 17. Install rear hub and bearing assembly onto the rear spindle. Install a new hub and bearing assembly retaining nut. Torque hub and bearing assembly retaining nut to 217 Nm (160 ft. lbs.). Install the dust cap. 18. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 19. Install brake drum. Adjust and bleed service brakes 20. After brake drums are installed, pump brake pedal several times to do final adjustment of the brake shoe assemblies. 21. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 22. Repeat the procedure for the other side. 23. Test drive the vehicle, then visually inspect the rear brake to ensure no brake fluid leaks are present. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Page 5137 Axle Nut: Specifications Front Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 183 Nm (135 ft. lbs.) Rear Stub Axle To Hub Bearing Nut ........................................................................................................................................................ 217 Nm (160 ft. lbs.) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Lug Nut Torque Lug Nut Torque Lug Nuts 135 Nm Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation Air Door Actuator / Motor: Description and Operation The recirculation door actuator is a vacuum controlled actuator used to control movement of the recirculation door in air conditioned equipped vehicles. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Page 5146 Air Door Actuator / Motor: Service and Repair NOTE: The instrument panel must be removed from the vehicle to gain access to the recirculation door actuator. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" REMOVAL 1. Remove instrument panel from vehicle. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" Recirculation Door Actuator 2. Disconnect vacuum line from actuator. 3. Remove two nuts retaining vacuum actuator to recirculation door housing. 4. Disconnect actuator from recirc. door link. 5. Remove recirculation door actuator from vehicle. INSTALLATION For installation reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Adjustments > Mode Control Cable Adjustment Air Door Cable: Adjustments Mode Control Cable Adjustment 1. Attach cable to actuator arm on mode door and clip black casing against the stop. 2. Attach other end of cable to instrument panel control. 3. Turn the mode knob completely counterclockwise. 4. While holding the knob in the counterclockwise position, pull on the black casing of the mode cable. This will take up any free play in the cable and index the mode door to the mode knob. 5. Then snap the cable hold down clip into position. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Adjustments > Mode Control Cable Adjustment > Page 5151 Air Door Cable: Adjustments Temperature Control Cable Adjustment 1. Attach cable to actuator arm on temperature door and clip black casing against the stop. 2. Attach other end of cable to instrument panel control. 3. Turn the temperature knob completely counterclockwise. 4. While holding the knob in the counterclockwise position pull on the black casing of the temperature cable. This will take up any free play in the cable and index the temperature door to the temperature knob. 5. Then snap the cable hold down clip into position. 6. Remount control. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement Air Door Cable: Service and Repair Mode Control Cable Replacement NOTE: The Mode Control Cable can be removed and installed without having to remove the instrument panel from the vehicle. REMOVAL 1. Remove instrument panel upper cowl panel. Bezel Removal 2. Remove right side upper instrument panel bezel. Instrument Panel Center Vent 3. Remove center vent duct. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement > Page 5154 Instrument Panel Defrost Duct 4. Remove upper defrost duct. Instrument Panel Inner Defrost Duct Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement > Page 5155 5. Remove inner defrost duct. 6. Disconnect cable at heater unit. 7. Disconnect cable at control panel. 8. Remove cable from vehicle. INSTALLATION For installation, reverse the above procedures, adjust cable and test. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement > Page 5156 Air Door Cable: Service and Repair Temperature Control Cable Replacement NOTE: The Control Cable can be removed and installed without having to remove the instrument panel from the vehicle. REMOVAL 1. Remove instrument panel upper cowl panel. Bezel Removal 2. Remove right side upper instrument panel bezel. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" Instrument Panel Center Vent 3. Remove center vent duct. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement > Page 5157 Instrument Panel Defrost Duct 4. Remove upper defrost duct. Instrument Panel Inner Defrost Duct Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement > Page 5158 5. Remove inner defrost duct. 6. Disconnect cable at heater unit. 7. Disconnect cable at control panel. Remove control from instrument panel. 8. Remove cable from vehicle. INSTALLATION For installation reverse the above procedures, adjust cable and test. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 240397 > Mar > 97 > Blower Motor - Inoperative In Freezing Temps Blower Motor: Customer Interest Blower Motor - Inoperative In Freezing Temps NO: 24-03-97 GROUP: Heating & A/C DATE: Mar. 14, 1997 SUBJECT: Blower Motor Does Not Operate In Freezing Temperatures THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-20-96 DATED DECEMBER 20, 1996, WHICH SHOULD BE NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). A BLOWER MOTOR FOR A/C EQUIPPED VEHICLES HAS BEEN ADDED. MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT AFTER JULY 1, 1994 (MDH 07-01-XX), OR VEHICLES BUILT PRIOR TO JULY 1, 1994 (MDH 07-01-XX) THAT HAVE HAD TECHNICAL SERVICE BULLETIN 23-48-94 PERFORMED. TECHNICAL SERVICE BULLETIN 23-48-94 INCLUDES THE INSTALLATION OF A DRAIN TUBE. SYMPTOM/CONDITION: Blower motor may be inoperable in temperatures at/or below freezing. DIAGNOSIS: Inspect the blower motor fuse. If blown, inspect the blower motor for presence of ice or water. It may be necessary to park the vehicle in a warm area to allow the blower motor to begin to thaw and water to run out to verify the failure mode. If water or ice is found perform the Repair Procedure. PARTS REQUIRED: **AR(1) 04644918 Blower Motor (With Air Conditioning)** AR(1) 04644545 Blower Motor (Without Air Conditioning) AR(1) 04687835 Fuse, Blower Motor AR(1) 04783100 Drain Tube REPAIR PROCEDURE: This bulletin involves the positioning of the drain tube assembly and the replacement of the blower motor and blower motor fuse. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 240397 > Mar > 97 > Blower Motor - Inoperative In Freezing Temps > Page 5167 1. The drain tube is located up under the instrument panel to the left of the steering column. The tube should be routed as shown in Figure 1. 2. If the drain tube is pushed over or pinched as shown in Figure 2, pull the lower end of the drain and route as shown in Figure 1. If the drain tube will not straighten out to allow repositioning, the drain tube must be replaced. 3. Insure that the end of the drain tube is properly located down into the sill as far as possible without kinking the tube. 4. Replace the blower motor/wheel assembly by following the procedure in the 1997 Neon Service Manual (Publication Number 81-270-7025) starting on page 24-18. NOTE: THE BLOWER MOTOR RESISTOR AND CONNECTOR SHOULD BE CHECKED FOR SIGNS OF DAMAGE AND REPAIRED/REPLACED AS NEEDED. 5. Replace the blower motor fuse and insure blower motor is now operating properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-55-01-93 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 240397 > Mar > 97 > Blower Motor - Inoperative In Freezing Temps Blower Motor: All Technical Service Bulletins Blower Motor - Inoperative In Freezing Temps NO: 24-03-97 GROUP: Heating & A/C DATE: Mar. 14, 1997 SUBJECT: Blower Motor Does Not Operate In Freezing Temperatures THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-20-96 DATED DECEMBER 20, 1996, WHICH SHOULD BE NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). A BLOWER MOTOR FOR A/C EQUIPPED VEHICLES HAS BEEN ADDED. MODELS: 1995 - 1997 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT AFTER JULY 1, 1994 (MDH 07-01-XX), OR VEHICLES BUILT PRIOR TO JULY 1, 1994 (MDH 07-01-XX) THAT HAVE HAD TECHNICAL SERVICE BULLETIN 23-48-94 PERFORMED. TECHNICAL SERVICE BULLETIN 23-48-94 INCLUDES THE INSTALLATION OF A DRAIN TUBE. SYMPTOM/CONDITION: Blower motor may be inoperable in temperatures at/or below freezing. DIAGNOSIS: Inspect the blower motor fuse. If blown, inspect the blower motor for presence of ice or water. It may be necessary to park the vehicle in a warm area to allow the blower motor to begin to thaw and water to run out to verify the failure mode. If water or ice is found perform the Repair Procedure. PARTS REQUIRED: **AR(1) 04644918 Blower Motor (With Air Conditioning)** AR(1) 04644545 Blower Motor (Without Air Conditioning) AR(1) 04687835 Fuse, Blower Motor AR(1) 04783100 Drain Tube REPAIR PROCEDURE: This bulletin involves the positioning of the drain tube assembly and the replacement of the blower motor and blower motor fuse. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 240397 > Mar > 97 > Blower Motor - Inoperative In Freezing Temps > Page 5173 1. The drain tube is located up under the instrument panel to the left of the steering column. The tube should be routed as shown in Figure 1. 2. If the drain tube is pushed over or pinched as shown in Figure 2, pull the lower end of the drain and route as shown in Figure 1. If the drain tube will not straighten out to allow repositioning, the drain tube must be replaced. 3. Insure that the end of the drain tube is properly located down into the sill as far as possible without kinking the tube. 4. Replace the blower motor/wheel assembly by following the procedure in the 1997 Neon Service Manual (Publication Number 81-270-7025) starting on page 24-18. NOTE: THE BLOWER MOTOR RESISTOR AND CONNECTOR SHOULD BE CHECKED FOR SIGNS OF DAMAGE AND REPAIRED/REPLACED AS NEEDED. 5. Replace the blower motor fuse and insure blower motor is now operating properly. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-55-01-93 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 5174 Blower Motor: Locations The blower motor is located on the bottom right side of the evaporator case unit housing. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Circuit Operation Blower Motor: Description and Operation Circuit Operation CIRCUIT OPERATION With the ignition switch in the RUN position, power flows from the 25 Amp fuse, in cavity 7 of the fuse block, to the blower motor. Blower motor speed is controlled by the fan control switch located in the instrument panel, and the resistor block. Blower motor LOW speed operation is accomplished on the C4 circuit. When the control switch is moved to the LOW speed position, current is on the C7 circuit through the blower motor resistor to the C4 circuit. It then flows through the blower motor switch to the Z8 circuit. The Z8 circuit terminates at a grounding point on the instrument panel left center support. The operation of the blower motor M1 and M2 speed operations is the same as the LOW speed except, the C5 circuit is used for the M1 speed and circuit C6 is used for M2 speed operation. Blower motor HIGH speed operation is accomplished on the C7 circuit which supplies battery voltage directly to the blower motor. There are no resistors used in the HIGH speed mode. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Circuit Operation > Page 5177 Blower Motor: Description and Operation System Operation BLOWER MOTOR OPERATION With the ignition switch in the RUN position, power flows from the 25 amp fuse, in cavity 7 of the fuse block, to the blower motor. Blower motor speed is controlled by the fan control switch located in the instrument panel, and by the resistor block. Blower motor low-speed operation is accomplished on the C4 circuit. When the control switch is moved to the low-speed position, current flows from the C7 circuit, through the blower motor resistor, to the C4 circuit. It then flows through the blower motor switch to the Z8 circuit. The Z8 circuit terminates at a grounding point located at the instrument panel left center support. The operation of the blower motor M1 and M2 speed operations is the same as the low-speed except that circuit C5 is used for the M1 speed, and circuit C6 is used for M2 speed operation. Blower motor high-speed operation is accomplished on the C7 circuit, which supplies battery voltage directly to the blower motor There are no resistors used in the high-speed mode. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and Inspection > Flow of Diagnosis Blower Motor: Flow of Diagnosis Blower Motor Noise and Vibration Diagnosis Blower Motor Noise/Vibration Diagnosis The resistor block supplies the blower motor with varied voltage (low and middle speeds) or battery voltage (high speed). CAUTION: Blower motor resistor block can be very hot, use caution when working on or near it. Do not operate the blower motor with the resistor block removed from the heater-A/C housing. Refer to the Blower Motor Vioration/Noise chart for diagnosis. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and Inspection > Flow of Diagnosis > Page 5180 Blower Motor Electrical Diagnosis Blower Motor Electrical Diagnosis For Blower motor electrical diagnosis refer to the above chart and also see Diagrams/Electrial. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and Inspection > Flow of Diagnosis > Page 5181 Blower Motor: Component Tests and General Diagnostics - Check the 30 Amp fuse located in the Power Distribution Center (PDC) for the radiator fan motor. - Check the 15 Amp fuse located in cavity 10 of the fuse block for radiator fan and A/C compressor clutch relays. - Check the 10 Amp fuse located in the PDC for the A/C compressor clutch relay. - Check the 25 Amp fuse located in cavity 7 of the fuse block for the blower motor. - Check the right headlamp ground located at the right fender side shield. - Check the left headlamp ground located on the left side of the radiator closure panel. - On vehicles equipped with A/C check the refrigerant level. The system will not operate with a low level of refrigerant. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > With A/C Blower Motor: Service and Repair With A/C NOTE: The blower motor can be removed from the vehicle without having to remove the unit housing assembly REMOVAL 1. Remove right side scuff plate. 2. Pull back carpet. 3. Cut wheel housing silencer in line with blower motor wiring. 4. Disconnect blower motor wiring connector. 5. Right Hand Drive (RHD) vehicle remove the motor cover. Blower Motor Retaining Screws 6. Remove three blower motor retaining screws. 7. Lower blower motor assembly from unit housing. INSTALLATION For installation, reverse the above procedures. Then tape silencer into position. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > With A/C > Page 5184 Blower Motor: Service and Repair Without A/C REMOVAL 1. Disconnect blower motor wiring connector. Blower Motor Removal 2. Grasp the blower motor while pulling down tab. Turn approximately 1/8 turn counterclockwise and remove blower motor assembly from unit housing. INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Resistor Block The blower motor resistor is located in the cowl, at the base of the windshield. There are two different resistor blocks depending on whether the vehicle is equipped with A/C or not. WARNING: The blower motor resistors will get hot when in use. Do not touch resistor block if the blower motor has been running. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 5188 Blower Motor Resistor: Service and Repair CAUTION: Blower motor resistor block can be very hot, use caution when working on or near it. Do not operate the blower motor with the resistor block removed. REMOVAL 1. Remove windshield wipers. 2. Remove cowl top screen. 3. Disconnect the resistor block wiring connector. 4. Remove two resistor block retaining screws. The screw threads attaching the resistor block are not full length. It is necessary to gently pry out the resistor block while turning the screws counterclockwise enabling the threads to engages. 5. Remove resistor block from vehicle. INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Description and Operation > A/C Clutch Relay Operation Compressor Clutch: Description and Operation A/C Clutch Relay Operation Theory of Operation: The A/C compressor clutch relay controls the 12 volt source for the A/C clutch. The relay is located in the power distribution center. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the run position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). When A/C is requested, the PCM adjusts the idle speed to accommodate the A/C compressor load on the engine. The PCM grounds the relay control circuit after the PCM receives an A/C request and adjustment of the idle speed has been implemented. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Description and Operation > A/C Clutch Relay Operation > Page 5194 Compressor Clutch: Description and Operation Related Trouble Codes and Set Conditions A/C Clutch Relay Circuit Name of Code: A/C Clutch Relay Circuit When Monitored: With the ignition key in the run position and battery voltage above 10 volts. Set Condition: An open or shorted condition is detected in the A/C clutch relay control circuit. Theory of Operation: The A/C compressor clutch relay controls the 12 volt source for the A/C clutch. The relay is located in the power distribution center. One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the run position. The circuit is completed when the other side of the relay coil is grounded by the powertrain control module (PCM). When A/C is requested, the PCM adjusts the idle speed to accommodate the A/C compressor load on the engine. The PCM grounds the relay control circuit after the PCM receives an A/C request and adjustment of the idle speed has been implemented. Possible Causes: - Relay coil open or shorted - Fused ignition switch output circuit open - Compressor clutch relay control circuit open or shorted - Inoperative circuit driver in powertrain control module A/C Pressure Sensor Volts Too High Name of Code: A/C Pressure Sensor Volts Too High When Monitored: With the ignition on, the engine running, and the A/C relay energized, Set Condition: The A/C pressure sensor signal at PCM cavity 42 goes above 4.9 volts. Theory of Operation: The A/C pressure sensor informs the PCM if the A/C system pressure is too low or too high. This information allows the PCM to determine if it can engage the compressor clutch. If the A/C system pressure is too low, the PCM will not engage the compressor clutch. If the system pressure is too high, the PCM will disengage the compressor clutch and turn on the cooling fans to prevent the compressor head pressure from becoming too high. The sensor provides a signal to PCM cavity 42. The sensor receives a 5-volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. Possible Causes: - Sensor signal open - Sensor internally open - PCM failure - Open sensor ground A/C Pressure Sensor Volts Too Low NAME OF CODE: A/C Pressure Sensor Volts Too Low WHEN MONITORED: With the ignition ON, the engine running, and the A/C relay energized. SET CONDITION: The A/C pressure sensor sensor signal at PCM cavity 42 goes below 0.7 volts. THEORY OF OPERATION: The A/C pressure sensor informs the PCM if the A/C system pressure is too low or too high. This information allows the PCM to determine if it can engage the compressor clutch. If the A/C system pressure is too low, the PCM will not engage the compressor clutch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Description and Operation > A/C Clutch Relay Operation > Page 5195 - If the system pressure is too high, the PCM will disengage the compressor clutch and turn on the cooling fans to prevent the compressor head pressure from becoming too high. The sensor provides a signal to PCM cavity 42. The sensor receives a 5 volt supply from PCM cavity 61. The sensor ground is provided by PCM cavity 43. POSSIBLE CAUSES: - Sensor signal shorted to ground - Sensor internally shorted - PCM failure Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Description and Operation > Page 5196 Compressor Clutch: Service and Repair REMOVAL NOTE: Compressor assembly must be removed from mounting. Although, refrigerant discharge is not necessary. Compressor Shaft Bolt And Clutch Plate 1. Remove the compressor shaft bolt. A band type oil filter removal tool can be placed around the clutch plate to aid in bolt removal. Clutch Plate And Shims 2. Tap the clutch plate with a plastic hammer and remove clutch plate and shim(s). CAUTION: Do not use screwdrivers between the clutch plate assembly and pulley to remove front plate as this may damage the front plate assembly. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Description and Operation > Page 5197 Removing Pulley Snap Ring 3. Remove pulley retaining snap ring with Snap Ring Pliers (C-4574), and slide pulley assembly off of compressor. 4. Remove coil wire bracket/ground clip screw and wire harness. Clutch Coil Snap Ring 5. Remove snap ring retaining field coil onto compressor housing. Slide field coil off of compressor housing. 6. Examine frictional faces of the clutch pulley and front plate for wear. The pulley and front plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft nose area of the compressor for oil and remove the felt from the front cover. If the compressor felt is saturated with oil, the shaft seal is leaking and will have to be replaced. 7. Check bearing for roughness or excessive leakage of grease. Replace bearing as required. INSTALLATION 1. Align pin in back of field coil with hole in compressor end housing, and position field coil into place. Make sure that lead wires are properly routed, and fasten the diode and coil wire bracket with retaining screw. 2. Install field coil retaining snap ring with Snap Ring Pliers (C- 4574). Press snap ring to make sure it is properly seated in the groove. NOTE: The bevel side of the snap ring must be outward. Also both eyelets must be to the right or left of the pin on the compressor. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Description and Operation > Page 5198 CAUTION: If snap ring is not fully seated it will vibrate out, resulting in a clutch failure and severe damage to the front face of the compressor. CAUTION: Do not mar the pulley frictional surface. Installing Pulley Assembly 3. Install pulley assembly to compressor. If necessary, tap gently with a block of wood on the friction surface. 4. Install pulley assembly retaining snap ring (bevel side outward) with Snap Ring Pliers (C-4574). Press the snap ring to make sure it is properly seated in the groove. NOTE: The bevel side of the snap ring must be facing outward. 5. If the original front plate assembly and pulley assembly are to be reused, the old shim(s) can be used. If not, place a trial stack of shims, 2.54 mm (0.10 in.) thick, on the shaft against the shoulder. 6. Install front plate assembly onto shaft. 7. If installing a new front plate and/or pulley assembly, the gap between front plate and pulley face must be checked. Use the following procedure: - Attach a dial indicator to front plate so that movement of the plate can be measured. - With the dial indicator zeroed on the front plate, energize the clutch and record the amount of movement. - The readings should be 0.35 to 0.65 mm (0.014 to 0.026 in.). If proper reading is not obtained, add or subtract shims until desired reading is obtained. 8. Install compressor shaft bolt. Tighten to 15.5 to 19.5 N.m (135 to 175 in. lbs.). NOTE: Shims may compress after tightening shaft nut. Check air gap in four or more places to verify if air gap is still correct. Spin pulley for final check. CLUTCH BREAK-IN After new clutch installation, cycle the A/C clutch 20 times (5 seconds ON and 5 seconds OFF). During this procedure, set the system to the A/C mode, engine rpm at 1500-2000, and high blower speed. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher clutch torque capability. NOTE: Excessive clutch gap will result in clutch slippage or non-engagement. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair Compressor Clutch Coil: Service and Repair REMOVAL NOTE: Compressor assembly must be removed from mounting. Although, refrigerant discharge is not necessary. Compressor Shaft Bolt And Clutch Plate 1. Remove the compressor shaft bolt. A band type oil filter removal tool can be placed around the clutch plate to aid in bolt removal. Clutch Plate And Shims 2. Tap the clutch plate with a plastic hammer and remove clutch plate and shim(s). CAUTION: Do not use screwdrivers between the clutch plate assembly and pulley to remove front plate as this may damage the front plate assembly. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 5202 Removing Pulley Snap Ring 3. Remove pulley retaining snap ring with Snap Ring Pliers (C-4574), and slide pulley assembly off of compressor. 4. Remove coil wire bracket/ground clip screw and wire harness. Clutch Coil Snap Ring 5. Remove snap ring retaining field coil onto compressor housing. Slide field coil off of compressor housing. 6. Examine frictional faces of the clutch pulley and front plate for wear. The pulley and front plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft nose area of the compressor for oil and remove the felt from the front cover. If the compressor felt is saturated with oil, the shaft seal is leaking and will have to be replaced. 7. Check bearing for roughness or excessive leakage of grease. Replace bearing as required. INSTALLATION 1. Align pin in back of field coil with hole in compressor end housing, and position field coil into place. Make sure that lead wires are properly routed, and fasten the diode and coil wire bracket with retaining screw. 2. Install field coil retaining snap ring with Snap Ring Pliers (C- 4574). Press snap ring to make sure it is properly seated in the groove. NOTE: The bevel side of the snap ring must be outward. Also both eyelets must be to the right or left of the pin on the compressor. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 5203 CAUTION: If snap ring is not fully seated it will vibrate out, resulting in a clutch failure and severe damage to the front face of the compressor. CAUTION: Do not mar the pulley frictional surface. Installing Pulley Assembly 3. Install pulley assembly to compressor. If necessary, tap gently with a block of wood on the friction surface. 4. Install pulley assembly retaining snap ring (bevel side outward) with Snap Ring Pliers (C-4574). Press the snap ring to make sure it is properly seated in the groove. NOTE: The bevel side of the snap ring must be facing outward. 5. If the original front plate assembly and pulley assembly are to be reused, the old shim(s) can be used. If not, place a trial stack of shims, 2.54 mm (0.10 in.) thick, on the shaft against the shoulder. 6. Install front plate assembly onto shaft. 7. If installing a new front plate and/or pulley assembly, the gap between front plate and pulley face must be checked. Use the following procedure: - Attach a dial indicator to front plate so that movement of the plate can be measured. - With the dial indicator zeroed on the front plate, energize the clutch and record the amount of movement. - The readings should be 0.35 to 0.65 mm (0.014 to 0.026 in.). If proper reading is not obtained, add or subtract shims until desired reading is obtained. 8. Install compressor shaft bolt. Tighten to 15.5 to 19.5 N.m (135 to 175 in. lbs.). NOTE: Shims may compress after tightening shaft nut. Check air gap in four or more places to verify if air gap is still correct. Spin pulley for final check. CLUTCH BREAK-IN After new clutch installation, cycle the A/C clutch 20 times (5 seconds ON and 5 seconds OFF). During this procedure, set the system to the A/C mode, engine rpm at 1500-2000, and high blower speed. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher clutch torque capability. NOTE: Excessive clutch gap will result in clutch slippage or non-engagement. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair Compressor Shaft Seal: Service and Repair COMPRESSOR FRONT SHAFT SEAL The compressor front shaft seal is not serviceable. If a leak is detected at the shaft seal, the compressor must be replaced as a unit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Power Distribution (Part 1 Of 2) Fig. 15 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair Condenser HVAC: Service and Repair The condenser is located in front of the engine radiator. It has no serviceable parts. If damaged or leaking, the condenser assembly must be replaced. WARNING: THE REFRIGERANT MUST BE REMOVED FROM THE SYSTEM BEFORE REMOVING THE CONDENSER. REMOVAL 1. Using a R-134a refrigerant recovery machine, remove the refrigerant from the A/C system. 2. Remove battery support strut. 3. Remove refrigerant lines from condenser. 4. Remove upper radiator mounts. 5. Remove condenser to radiator mounting screws. 6. Tilt radiator back and remove condenser. INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 5216 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 5217 Solid State Relay Solid State Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 5218 Condenser Fan Motor Relay: Description and Operation Radiator Fan Relay-PCM Output The PCM energizes the radiator fan through the radiator fan relay. The PCM controls the ground circuit for the solenoid side of the relay. Buss bars in the Power Distribution Center (PDC) supply voltage to the solenoid side and contact side of the relay. The radiator fan power circuit contains a 30 amp fuse between the buss bar in the PDC and the radiator fan relay. The fuse is located in the PDC. When engine coolant reaches a temperature of 99°C (210°F), the PCM energizes the radiator fan. The PCM turns the fan OFF when coolant temperature drops to 93°C (199°F). Whenever the PCM energizes the A/C compressor clutch it engages the fan. Also, to prevent radiator steaming, the PCM energizes the radiator fan at idle following certain cold starts. The radiator fan relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Radiator Fan Relay/Diagrams/Connector Views Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair Control Assembly: Service and Repair HEATER A/C CONTROL REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Using a trim stick (special tool #C-4755), gently pry up on the top cover and cluster bezel to remove. 3. Open the ash receiver. 4. Using a trim stick (special tool #C-4755), gently Pry out on the center bezel and remove. 5. Remove the six attaching screws across the forward portion of the right upper trim panel. Then pull the panel rearward to disengage the three locator pins and remove. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Page 5222 6. Reach in and disconnect the wiring connector(s) for the rear window defogger and/or fog lamp switch(s) as required. 7. If equipped with RKE, remove the two screws retaining the module and lay over the instrument cluster. 8. Gently pull on the center A/C outlet duct to remove. 9. Remove three attaching screws at corners of the control, two front retaining and one retaining from the top rear. 10. Pull the control rearward and disconnect the wiring connector. 11. Using a screwdriver, disengage the cable attachment clips. INSTALLATION 1. For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors Technical Service Bulletin # 24-11-97 Date: 970711 A/C Evaporator - Emits Odors NO: 24-11-97 GROUP: Heater & A/C DATE: Jul. 11, 1997 SUBJECT: A/C Evaporator Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 REV. A, DATED MAY 26, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1995 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-96084). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1992 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1998 (AB) Ram Van/Wagon 1992 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1992 - 1993 (AG) Daytona 1992 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1998 (AN) Dakota 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1998 (BR) Ram Pickup 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1998 (GS) Chrysler Voyager (International Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1995 - 1998 (PL) Neon 1997 - 1998 (TJ) Wrangler 1992 - 1998 (XJ) Cherokee 1994 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the evaporator core. During normal A/C system operation, condensation forms in and around the A/C evaporator. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: Operate the A/C system, if a musty odor is experienced, perform the Repair Procedure. PARTS REQUIRED: 1 O4897625AA Cleaner, Aerosol Evaporator POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-93 AA, AC, AG, AJ, AY, PL, TJ, XJ, ZJ 0.7 Hrs. AB, AN, AP, BR, GS, JA, JX, NS 0.6 Hrs. LH 1.5 Hrs. AS, ES 1.0 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 5231 Repair Procedure This bulletin involves inspecting for leaves or other foreign material in the evaporator and HVAC housing and applying Mopar aerosol evaporator cleaner. NOTE: FOLLOW ALL CAUTIONS AND WARNING SUPPLIED WITH THE AEROSOL EVAPORATOR CLEANER; KEEP OUT OF REACH OF CHILDREN; AVOID CONTACT WITH SKIN OR EYES; WEAR SKIN AND EYE PROTECTION, IF SKIN OR EYE CONTACT OCCURS, WASH SKIN OR FLUSH EYES WITH GENEROUS AMOUNTS OF WATER; AVOID BREATHING VAPORS. 1. Inspect the evaporator and HVAC housing for leaves or other foreign material that may be blocking the air flow through the evaporator. If the build up is excessive replacement of the evaporator may be required. 2. With the parking brake applied and the transmission in Park, start the engine and let idle. Put the temperature control to full hot, blower speed to HIGH, select the PANEL and RE-CIRCULATE modes. Open all windows about 13 mm (1/2 in.). Disable the A/C compressor clutch by disconnecting its wiring connector or the wiring connector to the A/C pressure switch. NOTE: THIS PROCEDURE HEATS THE EVAPORATOR AND CAUSES MOISTURE TO EVAPORATE FASTER. THE SLIGHTLY OPEN WINDOWS ALLOW MOISTURE TO ESCAPE THE VEHICLE WITHOUT LOOSING MUCH HEAT. SOMETIMES, YOU MAY SEE A "FOG" CLOUDING THE WINDOWS. AFTER THIS "FOG" HAS DISAPPEARED CONTINUE TO OPERATE THE HEATER FOR ANOTHER 5 MINUTES. IF THE "FOG" NEVER APPEARED, OPERATE THE HEATER FOR A MINIMUM OF 30 MINUTES. 3. Turn the ignition switch to the OFF position. 4. Gain access to the evaporator cavity to apply the evaporator cleaner by: AB, 1992-93 AN, GS, JA, JX, LH, NS and PL - Remove evaporator fin temperature sensor access grommet. DO NOT REMOVE THE PROBE FROM THE EVAPORATOR. BR, TJ, XJ, ZG, ZJ - Remove blower resistor. For the above vehicles, place a piece of heavy masking tape over the opening in the evaporator housing where the fin temperature sensor access grommet or blower resistor was removed, then punch a small hole for the evaporator cleaner tube to be inserted into. AA, AC, AG, AJ, AP, and AY - Remove the screw attaching the right side floor duct. Use an 1/8 in. drill bit to drill through the bottom of the screw hole, Figure 1. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 5232 1994-98 AN - Drill an 1/8 in. hole at the mid-point of the rounded corner created by the intersection of the vertical and horizontal surfaces of the HVAC housing, refer to Figure 2. Place tape around the drill bit to prevent the bit from entering the housing more a 1/4 in. AS, ES - Remove the lower right instrument panel. Remove the blower motor cover. Make a template as illustrated below and drill an 1/8 in. hole as shown in Figure 3. Be sure to angle drill as illustrated. Shake evaporator cleaner aerosol can well and insert the application tube in the access hole created in step 3. NOTE: THE APPLICATION TUBE HAS A BLACK MARK AND A RED MARK ON IT INDICATING HOW FAR THE TUBE SHOULD BE INSERTED INTO THE EVAPORATOR CAVITY. THE RED MARK IS FOR AA, AC, AG, AJ, AP, AND AY BODY VEHICLES. THE BLACK MARK IS FOR ALL OTHER VEHICLES. 5. Start the engine and let idle. Set the blower motor to HIGH. 6. Put on goggles and dust mask type breathing protection. 7. Spray the entire contents of the evaporator cleaner into the evaporator cavity. NOTE: A "FOG" MAY BE SEEN ENTERING THE PASSENGER COMPARTMENT WHILE THE EVAPORATOR CLEANER IS BEING SPRAYED. THE EVAPORATOR CLEANER WILL NOT STAIN OR HARM THE VEHICLE INTERIOR, BUT GOGGLES AND BREATHING PROTECTION MUST BE WORN DURING CLEANER APPLICATION. DO NOT BREATH VAPORS! 8. When the can is empty, turn the ignition switch to the OFF position and let the vehicle sit for 20 minutes. This time will allow the cleaner to flow over and coat the evaporator fins and case assembly. 9. Install whatever components that were removed to gain access for application of the cleaner. On AS, ES and 1994-1998 AN, seal the access hole drilled in step 3 NOTE: OWNERS OF NS/GS VEHICLES THAT OPERATE IN CONDITIONS WHERE THE AIR INLET TO THE HVAC HOUSING IS SUBJECT TO FOREIGN MATERIAL, DEBRIS OR OTHER AIRBORNE CONTAMINATES, MAY WANT TO CONSIDER HAVING A MOPAR ACCESSORY CABIN AIR FILTER KIT INSTALLED, P/N 82202509. USE THE INSTRUCTIONS PACKAGED WITH THE KIT TO INSTALL IT. 10. Open all of the vehicle windows about 13 mm (1/2 in.). Start the engine and let idle for a MINIMUM of 30 minutes with the temperature control to full hot, blower speed to HIGH, PANEL and RE-CIRCULATE modes selected. This will dry and cure the evaporator cleaner onto the evaporator coil. 11. Connect the wiring disconnected in step 2 to re-enable the A/C compressor clutch. 12. Verify proper A/C operation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors Technical Service Bulletin # 24-11-97 Date: 970711 A/C Evaporator - Emits Odors NO: 24-11-97 GROUP: Heater & A/C DATE: Jul. 11, 1997 SUBJECT: A/C Evaporator Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 REV. A, DATED MAY 26, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1995 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-96084). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1992 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1998 (AB) Ram Van/Wagon 1992 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1992 - 1993 (AG) Daytona 1992 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1998 (AN) Dakota 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1998 (BR) Ram Pickup 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1998 (GS) Chrysler Voyager (International Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1995 - 1998 (PL) Neon 1997 - 1998 (TJ) Wrangler 1992 - 1998 (XJ) Cherokee 1994 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the evaporator core. During normal A/C system operation, condensation forms in and around the A/C evaporator. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: Operate the A/C system, if a musty odor is experienced, perform the Repair Procedure. PARTS REQUIRED: 1 O4897625AA Cleaner, Aerosol Evaporator POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-93 AA, AC, AG, AJ, AY, PL, TJ, XJ, ZJ 0.7 Hrs. AB, AN, AP, BR, GS, JA, JX, NS 0.6 Hrs. LH 1.5 Hrs. AS, ES 1.0 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 5238 Repair Procedure This bulletin involves inspecting for leaves or other foreign material in the evaporator and HVAC housing and applying Mopar aerosol evaporator cleaner. NOTE: FOLLOW ALL CAUTIONS AND WARNING SUPPLIED WITH THE AEROSOL EVAPORATOR CLEANER; KEEP OUT OF REACH OF CHILDREN; AVOID CONTACT WITH SKIN OR EYES; WEAR SKIN AND EYE PROTECTION, IF SKIN OR EYE CONTACT OCCURS, WASH SKIN OR FLUSH EYES WITH GENEROUS AMOUNTS OF WATER; AVOID BREATHING VAPORS. 1. Inspect the evaporator and HVAC housing for leaves or other foreign material that may be blocking the air flow through the evaporator. If the build up is excessive replacement of the evaporator may be required. 2. With the parking brake applied and the transmission in Park, start the engine and let idle. Put the temperature control to full hot, blower speed to HIGH, select the PANEL and RE-CIRCULATE modes. Open all windows about 13 mm (1/2 in.). Disable the A/C compressor clutch by disconnecting its wiring connector or the wiring connector to the A/C pressure switch. NOTE: THIS PROCEDURE HEATS THE EVAPORATOR AND CAUSES MOISTURE TO EVAPORATE FASTER. THE SLIGHTLY OPEN WINDOWS ALLOW MOISTURE TO ESCAPE THE VEHICLE WITHOUT LOOSING MUCH HEAT. SOMETIMES, YOU MAY SEE A "FOG" CLOUDING THE WINDOWS. AFTER THIS "FOG" HAS DISAPPEARED CONTINUE TO OPERATE THE HEATER FOR ANOTHER 5 MINUTES. IF THE "FOG" NEVER APPEARED, OPERATE THE HEATER FOR A MINIMUM OF 30 MINUTES. 3. Turn the ignition switch to the OFF position. 4. Gain access to the evaporator cavity to apply the evaporator cleaner by: AB, 1992-93 AN, GS, JA, JX, LH, NS and PL - Remove evaporator fin temperature sensor access grommet. DO NOT REMOVE THE PROBE FROM THE EVAPORATOR. BR, TJ, XJ, ZG, ZJ - Remove blower resistor. For the above vehicles, place a piece of heavy masking tape over the opening in the evaporator housing where the fin temperature sensor access grommet or blower resistor was removed, then punch a small hole for the evaporator cleaner tube to be inserted into. AA, AC, AG, AJ, AP, and AY - Remove the screw attaching the right side floor duct. Use an 1/8 in. drill bit to drill through the bottom of the screw hole, Figure 1. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 5239 1994-98 AN - Drill an 1/8 in. hole at the mid-point of the rounded corner created by the intersection of the vertical and horizontal surfaces of the HVAC housing, refer to Figure 2. Place tape around the drill bit to prevent the bit from entering the housing more a 1/4 in. AS, ES - Remove the lower right instrument panel. Remove the blower motor cover. Make a template as illustrated below and drill an 1/8 in. hole as shown in Figure 3. Be sure to angle drill as illustrated. Shake evaporator cleaner aerosol can well and insert the application tube in the access hole created in step 3. NOTE: THE APPLICATION TUBE HAS A BLACK MARK AND A RED MARK ON IT INDICATING HOW FAR THE TUBE SHOULD BE INSERTED INTO THE EVAPORATOR CAVITY. THE RED MARK IS FOR AA, AC, AG, AJ, AP, AND AY BODY VEHICLES. THE BLACK MARK IS FOR ALL OTHER VEHICLES. 5. Start the engine and let idle. Set the blower motor to HIGH. 6. Put on goggles and dust mask type breathing protection. 7. Spray the entire contents of the evaporator cleaner into the evaporator cavity. NOTE: A "FOG" MAY BE SEEN ENTERING THE PASSENGER COMPARTMENT WHILE THE EVAPORATOR CLEANER IS BEING SPRAYED. THE EVAPORATOR CLEANER WILL NOT STAIN OR HARM THE VEHICLE INTERIOR, BUT GOGGLES AND BREATHING PROTECTION MUST BE WORN DURING CLEANER APPLICATION. DO NOT BREATH VAPORS! 8. When the can is empty, turn the ignition switch to the OFF position and let the vehicle sit for 20 minutes. This time will allow the cleaner to flow over and coat the evaporator fins and case assembly. 9. Install whatever components that were removed to gain access for application of the cleaner. On AS, ES and 1994-1998 AN, seal the access hole drilled in step 3 NOTE: OWNERS OF NS/GS VEHICLES THAT OPERATE IN CONDITIONS WHERE THE AIR INLET TO THE HVAC HOUSING IS SUBJECT TO FOREIGN MATERIAL, DEBRIS OR OTHER AIRBORNE CONTAMINATES, MAY WANT TO CONSIDER HAVING A MOPAR ACCESSORY CABIN AIR FILTER KIT INSTALLED, P/N 82202509. USE THE INSTRUCTIONS PACKAGED WITH THE KIT TO INSTALL IT. 10. Open all of the vehicle windows about 13 mm (1/2 in.). Start the engine and let idle for a MINIMUM of 30 minutes with the temperature control to full hot, blower speed to HIGH, PANEL and RE-CIRCULATE modes selected. This will dry and cure the evaporator cleaner onto the evaporator coil. 11. Connect the wiring disconnected in step 2 to re-enable the A/C compressor clutch. 12. Verify proper A/C operation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5248 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5249 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5250 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5251 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5252 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5253 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5254 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5255 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5256 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5257 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5258 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5259 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 240795A > Feb > 96 > A/C Evaporator - High Pitched Whistle Evaporator Core: Customer Interest A/C Evaporator - High Pitched Whistle NO: 24-07-95 Rev. A GROUP: Heater & A/C DATE: Feb. 9, 1996 SUBJECT: A/C Evaporator High Pitch Whistle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-95 DATED MAY 12, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE PART NUMBER FOR THE A/C EXPANSION VALVE HAS BEEN REVISED AND THE 1996 MODEL YEAR HAS BEEN ADDED. ALL CHANGES ARE MARKED WITH ** ASTERISKS **. MODELS: 1995 - **1996** (PL) Neon SYMPTOM/CONDITION: Under certain conditions, the internal flow of R-134a refrigerant may set up a resonance in some evaporator cores. This resonance can emit from the dash area as a high- pitched whistle noise. The whistle noise usually lasts 3 to 5 seconds and starts shortly after the A/C compressor clutch engages. The duration and the intensity of the whistle noise may vary as well as be highly intermittent. The whistle noise is most likely to be experienced in ambient temperatures above 85 degrees Fahrenheit and engine speeds of 2,000 RPM or higher. DIAGNOSIS: Diagnosis may be very difficult due to the intermittent nature of the whistle condition. If an ambient temperature of 85 degrees Fahrenheit or higher and high humidity are present; set the Heater-A/C controls to A/C, OUTSIDE AIR, with the temperature control at "full cool" and blower on "low". Raise the engine speed to between 2,500 to 3,000 RPM and listen for the condition to occur at the beginning of each A/C clutch cycle. If the "whistle" noise occurs, proceed to the repair procedure. If ambient temperatures of 85 degrees Fahrenheit or higher and high humidity are not present, have the vehicle owner describe in detail the conditions in which they experience the whistle. Proceed to the following diagnostic procedure. A. Verify that the A/C system is functioning properly by performing the System Charge Level procedure outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 24-7 through 24-8. B. The engine should be at normal operating temperature and the vehicle should be in a quiet location with all windows and doors closed. C. Set the Heater-A/C controls to FLOOR, RECIRC, with the temperature control at "full heat" and blower on "high heat", A/C off. D. Run the vehicle until the interior temperature reaches at least 110 degrees Fahrenheit. E. Raise the engine speed to between 2,500 to 3,000 RPM and maintain. Switch the Heater-A/C blower control to "low A/C". F. Listen for the condition to occur at the beginning of each A/C compressor clutch cycle. If the "whistle" is heard, proceed to the repair procedure. PARTS REQUIRED: **1 5264744 Valve, A/C Expansion, With Bleed** 1 4677045 Gasket, A/C Expansion Valve To Evaporator 1 3846834 Gasket, A/C Expansion Valve To Refrigerant Line AR 82300102 R-134a Compressor Oil (PAG-ND8) AR 4797130 Coil, A/C Evaporator REPAIR PROCEDURE: This bulletin involves installing a different type of expansion valve, the addition of extra compressor lubricant and, if necessary, the A/C evaporator coil. **1. If the vehicle is a 1996 Model Year vehicle and contains the new expansion valve (P/N 5264744) and compressor (P/N 5264745) proceed to step 19.** 2. Recover the R-134a refrigerant while completely discharging the A/C system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 240795A > Feb > 96 > A/C Evaporator - High Pitched Whistle > Page 5264 WARNING: THE A/C SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS OPERATION. 3. Remove the boot-type wire connector from the low pressure cut-off switch which is part of the expansion valve. 4. Remove the bolt in the center of the refrigerant line sealing plate. 5. Carefully pull the refrigerant line sealing plate from the expansion valve. 6. Cover the openings on refrigerant line sealing plate to prevent contamination or damage. 7. Remove the two screws attaching the expansion valve to the evaporator sealing plate. 8. Carefully remove the expansion valve and the two aluminum gaskets. Remove the Low Pressure Cut-off switch from the old expansion valve and install it on the **new expansion valve, P/N 5264744.** 9. Place a new gasket, PIN 4677045, on the evaporator sealing plate and install the ** new expansion valve, P/N 5264744.** DO NOT SCRATCH THE SEALING SURFACES of the new expansion valve. Install the two attaching screw and torque to 70 - 130 in. lbs (8 - 14 Nm). 10. Add two ounces of PAG-ND8, P/N 82300102, oil into the suction line. 11. Place a new gasket, P/N 3846834, on the refrigerant line sealing plate. 12. Carefully hold the refrigerant line sealing plate to the expansion valve, DO NOT SCRATCH THE SEALING SURFACES. Install the attaching bolt and torque to 170 - 230 in. lbs. (20 - 26 Nm.). 13. Connect the wire connectors to the low pressure cut-off switch. 14. Evacuate and recharge the A/C system. Proceed to the following steps to verify that the condition has been corrected. 15. The engine should be at normal operating temperature and the vehicle should be in a quiet location with all windows and doors closed. 16. Set the Heater-A/C controls to FLOOR, RECIRC, with the temperature control at "full heat" and blower on "high heat", A/C off. 17. Run the vehicle until the interior temperature reaches at least 110 degrees Fahrenheit. 18. Raise the engine speed to between 2,500 to 3,000 RPM and maintain. Switch the Heater-A/C blower control to "low A/C". 19. Listen for the condition to occur at the beginning of each A/C compressor clutch cycle. If the "whistle" is still exists replace the A/C evaporator coil, P/N 4797130 as outlined in the Service Manual, Pages 24-23 through 24-24. NOTE: USE NEW EXPANSION VALVE GASKETS PIN 4677045 AND 3846834 BUT DO NOT REPLACE THE EXPANSION VALVE A SECOND TIME. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE:Valve, A/C Expansion Valve, Replace & Add Oil Labor Operation No: 24-35-20-90 1.1 Hrs. Coil, Evaporator, Replace 24-65-02-96 4.0 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5270 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5271 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5272 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5273 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5274 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5275 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5276 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5277 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5278 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5279 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5280 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 5281 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 241496 > Sep > 96 > A/C , Heater - Odors/Defroster Will Not Clear Glass Evaporator Core: All Technical Service Bulletins A/C , Heater - Odors/Defroster Will Not Clear Glass NO: 24-14-96 GROUP: Heater & A/C DATE: Sep. 27, 1996 SUBJECT: A/C Evaporator Odor And/Or Incomplete Defrost In "Recirc" Mode MODELS: 1995 - 1997 (PL) Neon 1995 - 1997 (JA) Stratus/Cirrus/Breeze 1996 - 1997 (JX) Sebring Convertible SYMPTOM/CONDITION: A temporary musty odor may be emitted from the A/C ducts and/or the defroster may not be able to completely clear all the glass, when the recirculation mode (Recirc) is used for extended periods of time. DISCUSSION: The vehicles listed above offer a separate rotary knob for independent control of the Fresh (outside air) / "Recirc" (inside air) function. The intent of the independent control of Recirc is: ^ To temporarily allow customers to eliminate dust or outside odors. ^ To get maximum cooldown performance by going into "Recirc" without having to change modes or temperature settings. Prior to January 1995, the A/C evaporator had a chromate coating for long term corrosion protection and a silicate coating to insure that condensate would run off the fins instead of getting in the airstream and coming out the panel outlets. Due to new regulations, a new non-chromate coating process was implemented in January 1995. Under some ambient conditions the new coating may cause the air passing over the evaporator to develop a temporary musty odor. When operated in the "Recirc mode the odor is more noticeable. Also, operating for extended periods in "Recirc" with the A/C off may create and intensify the musty odor. Running in "Recirc" for long periods of time in very cold weather may cause moisture from snow tracked into the car and moisture from the occupants breath to condense on the cold glass and in some cases the defroster may not clear all the glass. Even with the A/C running on mild wet days and running in "Recirc" some fog may remain on areas of the glass. NOTE: CHANGES IN THE 1997 NEON WILL NOT ALLOW THE FRESH/RECIRC DOOR TO STAY IN RECIRC WHEN THE DEFROST MODE IS SELECTED. It is important that the instructions given in the owners manual that recommend that the "Recirc" mode be used for no more than 30 minutes at a time be followed. Encourage customers to operate in Fresh as the normal condition and go to Recirc only for the temporary conditions given above. POLICY: Information only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 240795A > Feb > 96 > A/C Evaporator - High Pitched Whistle Evaporator Core: All Technical Service Bulletins A/C Evaporator - High Pitched Whistle NO: 24-07-95 Rev. A GROUP: Heater & A/C DATE: Feb. 9, 1996 SUBJECT: A/C Evaporator High Pitch Whistle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-95 DATED MAY 12, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE PART NUMBER FOR THE A/C EXPANSION VALVE HAS BEEN REVISED AND THE 1996 MODEL YEAR HAS BEEN ADDED. ALL CHANGES ARE MARKED WITH ** ASTERISKS **. MODELS: 1995 - **1996** (PL) Neon SYMPTOM/CONDITION: Under certain conditions, the internal flow of R-134a refrigerant may set up a resonance in some evaporator cores. This resonance can emit from the dash area as a high- pitched whistle noise. The whistle noise usually lasts 3 to 5 seconds and starts shortly after the A/C compressor clutch engages. The duration and the intensity of the whistle noise may vary as well as be highly intermittent. The whistle noise is most likely to be experienced in ambient temperatures above 85 degrees Fahrenheit and engine speeds of 2,000 RPM or higher. DIAGNOSIS: Diagnosis may be very difficult due to the intermittent nature of the whistle condition. If an ambient temperature of 85 degrees Fahrenheit or higher and high humidity are present; set the Heater-A/C controls to A/C, OUTSIDE AIR, with the temperature control at "full cool" and blower on "low". Raise the engine speed to between 2,500 to 3,000 RPM and listen for the condition to occur at the beginning of each A/C clutch cycle. If the "whistle" noise occurs, proceed to the repair procedure. If ambient temperatures of 85 degrees Fahrenheit or higher and high humidity are not present, have the vehicle owner describe in detail the conditions in which they experience the whistle. Proceed to the following diagnostic procedure. A. Verify that the A/C system is functioning properly by performing the System Charge Level procedure outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 24-7 through 24-8. B. The engine should be at normal operating temperature and the vehicle should be in a quiet location with all windows and doors closed. C. Set the Heater-A/C controls to FLOOR, RECIRC, with the temperature control at "full heat" and blower on "high heat", A/C off. D. Run the vehicle until the interior temperature reaches at least 110 degrees Fahrenheit. E. Raise the engine speed to between 2,500 to 3,000 RPM and maintain. Switch the Heater-A/C blower control to "low A/C". F. Listen for the condition to occur at the beginning of each A/C compressor clutch cycle. If the "whistle" is heard, proceed to the repair procedure. PARTS REQUIRED: **1 5264744 Valve, A/C Expansion, With Bleed** 1 4677045 Gasket, A/C Expansion Valve To Evaporator 1 3846834 Gasket, A/C Expansion Valve To Refrigerant Line AR 82300102 R-134a Compressor Oil (PAG-ND8) AR 4797130 Coil, A/C Evaporator REPAIR PROCEDURE: This bulletin involves installing a different type of expansion valve, the addition of extra compressor lubricant and, if necessary, the A/C evaporator coil. **1. If the vehicle is a 1996 Model Year vehicle and contains the new expansion valve (P/N 5264744) and compressor (P/N 5264745) proceed to step 19.** 2. Recover the R-134a refrigerant while completely discharging the A/C system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 240795A > Feb > 96 > A/C Evaporator - High Pitched Whistle > Page 5290 WARNING: THE A/C SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS OPERATION. 3. Remove the boot-type wire connector from the low pressure cut-off switch which is part of the expansion valve. 4. Remove the bolt in the center of the refrigerant line sealing plate. 5. Carefully pull the refrigerant line sealing plate from the expansion valve. 6. Cover the openings on refrigerant line sealing plate to prevent contamination or damage. 7. Remove the two screws attaching the expansion valve to the evaporator sealing plate. 8. Carefully remove the expansion valve and the two aluminum gaskets. Remove the Low Pressure Cut-off switch from the old expansion valve and install it on the **new expansion valve, P/N 5264744.** 9. Place a new gasket, PIN 4677045, on the evaporator sealing plate and install the ** new expansion valve, P/N 5264744.** DO NOT SCRATCH THE SEALING SURFACES of the new expansion valve. Install the two attaching screw and torque to 70 - 130 in. lbs (8 - 14 Nm). 10. Add two ounces of PAG-ND8, P/N 82300102, oil into the suction line. 11. Place a new gasket, P/N 3846834, on the refrigerant line sealing plate. 12. Carefully hold the refrigerant line sealing plate to the expansion valve, DO NOT SCRATCH THE SEALING SURFACES. Install the attaching bolt and torque to 170 - 230 in. lbs. (20 - 26 Nm.). 13. Connect the wire connectors to the low pressure cut-off switch. 14. Evacuate and recharge the A/C system. Proceed to the following steps to verify that the condition has been corrected. 15. The engine should be at normal operating temperature and the vehicle should be in a quiet location with all windows and doors closed. 16. Set the Heater-A/C controls to FLOOR, RECIRC, with the temperature control at "full heat" and blower on "high heat", A/C off. 17. Run the vehicle until the interior temperature reaches at least 110 degrees Fahrenheit. 18. Raise the engine speed to between 2,500 to 3,000 RPM and maintain. Switch the Heater-A/C blower control to "low A/C". 19. Listen for the condition to occur at the beginning of each A/C compressor clutch cycle. If the "whistle" is still exists replace the A/C evaporator coil, P/N 4797130 as outlined in the Service Manual, Pages 24-23 through 24-24. NOTE: USE NEW EXPANSION VALVE GASKETS PIN 4677045 AND 3846834 BUT DO NOT REPLACE THE EXPANSION VALVE A SECOND TIME. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE:Valve, A/C Expansion Valve, Replace & Add Oil Labor Operation No: 24-35-20-90 1.1 Hrs. Coil, Evaporator, Replace 24-65-02-96 4.0 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 241496 > Sep > 96 > A/C , Heater - Odors/Defroster Will Not Clear Glass Evaporator Core: All Technical Service Bulletins A/C , Heater - Odors/Defroster Will Not Clear Glass NO: 24-14-96 GROUP: Heater & A/C DATE: Sep. 27, 1996 SUBJECT: A/C Evaporator Odor And/Or Incomplete Defrost In "Recirc" Mode MODELS: 1995 - 1997 (PL) Neon 1995 - 1997 (JA) Stratus/Cirrus/Breeze 1996 - 1997 (JX) Sebring Convertible SYMPTOM/CONDITION: A temporary musty odor may be emitted from the A/C ducts and/or the defroster may not be able to completely clear all the glass, when the recirculation mode (Recirc) is used for extended periods of time. DISCUSSION: The vehicles listed above offer a separate rotary knob for independent control of the Fresh (outside air) / "Recirc" (inside air) function. The intent of the independent control of Recirc is: ^ To temporarily allow customers to eliminate dust or outside odors. ^ To get maximum cooldown performance by going into "Recirc" without having to change modes or temperature settings. Prior to January 1995, the A/C evaporator had a chromate coating for long term corrosion protection and a silicate coating to insure that condensate would run off the fins instead of getting in the airstream and coming out the panel outlets. Due to new regulations, a new non-chromate coating process was implemented in January 1995. Under some ambient conditions the new coating may cause the air passing over the evaporator to develop a temporary musty odor. When operated in the "Recirc mode the odor is more noticeable. Also, operating for extended periods in "Recirc" with the A/C off may create and intensify the musty odor. Running in "Recirc" for long periods of time in very cold weather may cause moisture from snow tracked into the car and moisture from the occupants breath to condense on the cold glass and in some cases the defroster may not clear all the glass. Even with the A/C running on mild wet days and running in "Recirc" some fog may remain on areas of the glass. NOTE: CHANGES IN THE 1997 NEON WILL NOT ALLOW THE FRESH/RECIRC DOOR TO STAY IN RECIRC WHEN THE DEFROST MODE IS SELECTED. It is important that the instructions given in the owners manual that recommend that the "Recirc" mode be used for no more than 30 minutes at a time be followed. Encourage customers to operate in Fresh as the normal condition and go to Recirc only for the temporary conditions given above. POLICY: Information only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5296 Evaporator Core: Service and Repair This vehicle uses an aluminum plate and fin style evaporator. It is located in the Evaporator/Blower module. The unit housing must be removed from the vehicle before beginning with this procedure. Refer to: "Housing Assembly HVAC : Service and Repair" See: Housing Assembly HVAC/Service and Repair Use this procedure if any or all of the following items require service: - Evaporator - Air inlet duct - Recirculation door - Evaporator/Blower module case DISASSEMBLE 1. Remove the clips and screws that hold the Unit Housing to the Evaporator/Blower Module. Then separate the two units. Foam Seat Removal 2. Remove the evaporator to dash panel foam seal. 3. Disconnect fin sensing switch from harness. 4. Remove upper to lower case retaining clips and screws. Case Separation 5. Separate the case halves. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5297 Evaporator Removal 6. Lift the evaporator out of the module. ASSEMBLE To reassemble, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 241896 > Nov > 96 > Evaporator Drain - Water Leaks Into Interior Evaporator Drain Tube: Customer Interest Evaporator Drain - Water Leaks Into Interior NO: 24-18-96 GROUP: Heating & A/C DATE: Nov. 22, 1996 SUBJECT: Water Leaks Into Passenger Compartment Under I/P By A/C Drain MODELS: 1996 - 1997 (PL) Neon SYMPTOM/CONDITION: Water leaks into passenger compartment from under the right side of the instrument panel. DIAGNOSIS: Raise the vehicle on a hoist to allow access to the A/C condensate drain tube. The condensate drain tube should be pointing down toward the ground. If the tube is pointing elsewhere or if there are signs of moisture up near the A/C evaporator nipple, perform the Repair Procedure. PARTS REQUIRED: 1 82300234 RTV Sealant REPAIR PROCEDURE: This bulletin involves the positioning of the A/C condensate drain tube and sealing between the drain tube and A/C evaporator drain nipple. 1. Remove the drain tube from the NC evaporator nipple. Figure 1 2. Dry any moisture present and apply RTV (PIN 82300234) around the sealing diameter of the drain tube. 3. Install the drain tube onto the evaporator nipple. Insure the drain tube is pointing down toward the ground. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-03-93 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 241896 > Nov > 96 > Evaporator Drain Water Leaks Into Interior Evaporator Drain Tube: All Technical Service Bulletins Evaporator Drain - Water Leaks Into Interior NO: 24-18-96 GROUP: Heating & A/C DATE: Nov. 22, 1996 SUBJECT: Water Leaks Into Passenger Compartment Under I/P By A/C Drain MODELS: 1996 - 1997 (PL) Neon SYMPTOM/CONDITION: Water leaks into passenger compartment from under the right side of the instrument panel. DIAGNOSIS: Raise the vehicle on a hoist to allow access to the A/C condensate drain tube. The condensate drain tube should be pointing down toward the ground. If the tube is pointing elsewhere or if there are signs of moisture up near the A/C evaporator nipple, perform the Repair Procedure. PARTS REQUIRED: 1 82300234 RTV Sealant REPAIR PROCEDURE: This bulletin involves the positioning of the A/C condensate drain tube and sealing between the drain tube and A/C evaporator drain nipple. 1. Remove the drain tube from the NC evaporator nipple. Figure 1 2. Dry any moisture present and apply RTV (PIN 82300234) around the sealing diameter of the drain tube. 3. Install the drain tube onto the evaporator nipple. Insure the drain tube is pointing down toward the ground. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-03-93 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Locations Evaporator Temperature Sensor/Clutch Cycling Switch: Locations Evaporator Probe Location The evaporator probe is located in the Evaporator Case unit housing and placed in the evaporator fins. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions Evaporator Temperature Sensor/Clutch Cycling Switch: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5316 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5317 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5318 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5319 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5320 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5321 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5322 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5323 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5324 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5325 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5326 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5327 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5328 Evaporator Temperature Sensor/Clutch Cycling Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5329 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5330 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 5331 Evaporator Temperature Sensor/Clutch Cycling Switch: Description and Operation EVAPORATOR PROBE The evaporator probe can be replaced without having to remove the unit housing from the vehicle. The evaporator probe is located in the unit housing and placed in the evaporator fins. the probe prevents evaporator freeze-up. This is done by cycling the compressor clutch OFF when evaporator temperature rises above freeze point. It cycles ON when the evaporator temperature rises above freeze point. The evaporator probe uses a thermistor probe in a capillary tube. The tube is inserted between the evaporator fins in the heater-A/C unit housing. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 5332 Evaporator Temperature Sensor/Clutch Cycling Switch: Testing and Inspection CAUTION: The work area and vehicle must be between 16° C (60° F) and 32° C (90° F) when testing the switch. 1. Disconnect the three wire connector from the evaporator probe lead located behind the glove box. 2. Start engine and set A/C to low blower motor speed, panel, full cool, and RECIRC. Evaporator Probe Harness Connector 3. Using a voltmeter, check for battery voltage between Pin 1 and 2. If no voltage is detected, there is no power to the switch. Check wiring and fuses. 4. Using a voltmeter, check for battery voltage between Pin 1 and Pin 3. If no voltage is detected, there is no voltage from the Powertrain Control Module. If voltage is OK, connect a jumper wire between Pin 1 and Pin 3. The compressor clutch should engage. If the clutch engages, remove the jumper wire immediately and go to Step 5. If the compressor clutch does not engage, check the operation of the clutch and repair as necessary. 5. If compressor clutch engages, connect the evaporator probe 3-way connector. The compressor clutch should engage or cycle depending on evaporator temperature. If OK, go to Step 6. If not OK, replace the clutch cycling switch. 6. The engine running and the A/C set to: - Blower motor on low speed - Panel position - Full cool - RECIRC. - Close all doors and windows. Place a thermometer in the center discharge vent. 7. If the clutch does not begin to cycle off between 2° C to 7° C (35° F to 45° F), verify that the evaporator probe is fully installed and not loose in evaporator. If it is not properly installed, install probe and reset outlet temperature. If the evaporator probe is properly installed, replace the clutch cycling switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 5333 Evaporator Temperature Sensor/Clutch Cycling Switch: Service and Repair REMOVAL NOTE: The evaporator probe can be replaced without having to remove the unit housing from the vehicle. 1. Disconnect probe wiring connector from behind the glove box. Evaporator Probe Location 2. Remove rubber grommet from evaporator blower module. 3. Note in which of the three pilot holes the evaporator probe is located. 4. Pull probe out of evaporator fins. INSTALLATION 1. There are three pilot holes available for the probe. The top hole is for service. If top hole was not used by previous probe, install probe in top hole. 2. If previous probe was removed from top hole, use a small plastic stick and make a new hole. Make the hole 1/4 inch above or below the original hole in the evaporator core. 3. Insert new probe into hole between evaporator fins. 4. Reinstall rubber grommet into evaporator probe access hole. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 240795A > Feb > 96 > A/C Evaporator - High Pitched Whistle Expansion Valve: Customer Interest A/C Evaporator - High Pitched Whistle NO: 24-07-95 Rev. A GROUP: Heater & A/C DATE: Feb. 9, 1996 SUBJECT: A/C Evaporator High Pitch Whistle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-95 DATED MAY 12, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE PART NUMBER FOR THE A/C EXPANSION VALVE HAS BEEN REVISED AND THE 1996 MODEL YEAR HAS BEEN ADDED. ALL CHANGES ARE MARKED WITH ** ASTERISKS **. MODELS: 1995 - **1996** (PL) Neon SYMPTOM/CONDITION: Under certain conditions, the internal flow of R-134a refrigerant may set up a resonance in some evaporator cores. This resonance can emit from the dash area as a high- pitched whistle noise. The whistle noise usually lasts 3 to 5 seconds and starts shortly after the A/C compressor clutch engages. The duration and the intensity of the whistle noise may vary as well as be highly intermittent. The whistle noise is most likely to be experienced in ambient temperatures above 85 degrees Fahrenheit and engine speeds of 2,000 RPM or higher. DIAGNOSIS: Diagnosis may be very difficult due to the intermittent nature of the whistle condition. If an ambient temperature of 85 degrees Fahrenheit or higher and high humidity are present; set the Heater-A/C controls to A/C, OUTSIDE AIR, with the temperature control at "full cool" and blower on "low". Raise the engine speed to between 2,500 to 3,000 RPM and listen for the condition to occur at the beginning of each A/C clutch cycle. If the "whistle" noise occurs, proceed to the repair procedure. If ambient temperatures of 85 degrees Fahrenheit or higher and high humidity are not present, have the vehicle owner describe in detail the conditions in which they experience the whistle. Proceed to the following diagnostic procedure. A. Verify that the A/C system is functioning properly by performing the System Charge Level procedure outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 24-7 through 24-8. B. The engine should be at normal operating temperature and the vehicle should be in a quiet location with all windows and doors closed. C. Set the Heater-A/C controls to FLOOR, RECIRC, with the temperature control at "full heat" and blower on "high heat", A/C off. D. Run the vehicle until the interior temperature reaches at least 110 degrees Fahrenheit. E. Raise the engine speed to between 2,500 to 3,000 RPM and maintain. Switch the Heater-A/C blower control to "low A/C". F. Listen for the condition to occur at the beginning of each A/C compressor clutch cycle. If the "whistle" is heard, proceed to the repair procedure. PARTS REQUIRED: **1 5264744 Valve, A/C Expansion, With Bleed** 1 4677045 Gasket, A/C Expansion Valve To Evaporator 1 3846834 Gasket, A/C Expansion Valve To Refrigerant Line AR 82300102 R-134a Compressor Oil (PAG-ND8) AR 4797130 Coil, A/C Evaporator REPAIR PROCEDURE: This bulletin involves installing a different type of expansion valve, the addition of extra compressor lubricant and, if necessary, the A/C evaporator coil. **1. If the vehicle is a 1996 Model Year vehicle and contains the new expansion valve (P/N 5264744) and compressor (P/N 5264745) proceed to step 19.** 2. Recover the R-134a refrigerant while completely discharging the A/C system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Customer Interest for Expansion Valve: > 240795A > Feb > 96 > A/C Evaporator - High Pitched Whistle > Page 5342 WARNING: THE A/C SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS OPERATION. 3. Remove the boot-type wire connector from the low pressure cut-off switch which is part of the expansion valve. 4. Remove the bolt in the center of the refrigerant line sealing plate. 5. Carefully pull the refrigerant line sealing plate from the expansion valve. 6. Cover the openings on refrigerant line sealing plate to prevent contamination or damage. 7. Remove the two screws attaching the expansion valve to the evaporator sealing plate. 8. Carefully remove the expansion valve and the two aluminum gaskets. Remove the Low Pressure Cut-off switch from the old expansion valve and install it on the **new expansion valve, P/N 5264744.** 9. Place a new gasket, PIN 4677045, on the evaporator sealing plate and install the ** new expansion valve, P/N 5264744.** DO NOT SCRATCH THE SEALING SURFACES of the new expansion valve. Install the two attaching screw and torque to 70 - 130 in. lbs (8 - 14 Nm). 10. Add two ounces of PAG-ND8, P/N 82300102, oil into the suction line. 11. Place a new gasket, P/N 3846834, on the refrigerant line sealing plate. 12. Carefully hold the refrigerant line sealing plate to the expansion valve, DO NOT SCRATCH THE SEALING SURFACES. Install the attaching bolt and torque to 170 - 230 in. lbs. (20 - 26 Nm.). 13. Connect the wire connectors to the low pressure cut-off switch. 14. Evacuate and recharge the A/C system. Proceed to the following steps to verify that the condition has been corrected. 15. The engine should be at normal operating temperature and the vehicle should be in a quiet location with all windows and doors closed. 16. Set the Heater-A/C controls to FLOOR, RECIRC, with the temperature control at "full heat" and blower on "high heat", A/C off. 17. Run the vehicle until the interior temperature reaches at least 110 degrees Fahrenheit. 18. Raise the engine speed to between 2,500 to 3,000 RPM and maintain. Switch the Heater-A/C blower control to "low A/C". 19. Listen for the condition to occur at the beginning of each A/C compressor clutch cycle. If the "whistle" is still exists replace the A/C evaporator coil, P/N 4797130 as outlined in the Service Manual, Pages 24-23 through 24-24. NOTE: USE NEW EXPANSION VALVE GASKETS PIN 4677045 AND 3846834 BUT DO NOT REPLACE THE EXPANSION VALVE A SECOND TIME. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE:Valve, A/C Expansion Valve, Replace & Add Oil Labor Operation No: 24-35-20-90 1.1 Hrs. Coil, Evaporator, Replace 24-65-02-96 4.0 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 240795A > Feb > 96 > A/C Evaporator - High Pitched Whistle Expansion Valve: All Technical Service Bulletins A/C Evaporator - High Pitched Whistle NO: 24-07-95 Rev. A GROUP: Heater & A/C DATE: Feb. 9, 1996 SUBJECT: A/C Evaporator High Pitch Whistle NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-95 DATED MAY 12, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE PART NUMBER FOR THE A/C EXPANSION VALVE HAS BEEN REVISED AND THE 1996 MODEL YEAR HAS BEEN ADDED. ALL CHANGES ARE MARKED WITH ** ASTERISKS **. MODELS: 1995 - **1996** (PL) Neon SYMPTOM/CONDITION: Under certain conditions, the internal flow of R-134a refrigerant may set up a resonance in some evaporator cores. This resonance can emit from the dash area as a high- pitched whistle noise. The whistle noise usually lasts 3 to 5 seconds and starts shortly after the A/C compressor clutch engages. The duration and the intensity of the whistle noise may vary as well as be highly intermittent. The whistle noise is most likely to be experienced in ambient temperatures above 85 degrees Fahrenheit and engine speeds of 2,000 RPM or higher. DIAGNOSIS: Diagnosis may be very difficult due to the intermittent nature of the whistle condition. If an ambient temperature of 85 degrees Fahrenheit or higher and high humidity are present; set the Heater-A/C controls to A/C, OUTSIDE AIR, with the temperature control at "full cool" and blower on "low". Raise the engine speed to between 2,500 to 3,000 RPM and listen for the condition to occur at the beginning of each A/C clutch cycle. If the "whistle" noise occurs, proceed to the repair procedure. If ambient temperatures of 85 degrees Fahrenheit or higher and high humidity are not present, have the vehicle owner describe in detail the conditions in which they experience the whistle. Proceed to the following diagnostic procedure. A. Verify that the A/C system is functioning properly by performing the System Charge Level procedure outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pages 24-7 through 24-8. B. The engine should be at normal operating temperature and the vehicle should be in a quiet location with all windows and doors closed. C. Set the Heater-A/C controls to FLOOR, RECIRC, with the temperature control at "full heat" and blower on "high heat", A/C off. D. Run the vehicle until the interior temperature reaches at least 110 degrees Fahrenheit. E. Raise the engine speed to between 2,500 to 3,000 RPM and maintain. Switch the Heater-A/C blower control to "low A/C". F. Listen for the condition to occur at the beginning of each A/C compressor clutch cycle. If the "whistle" is heard, proceed to the repair procedure. PARTS REQUIRED: **1 5264744 Valve, A/C Expansion, With Bleed** 1 4677045 Gasket, A/C Expansion Valve To Evaporator 1 3846834 Gasket, A/C Expansion Valve To Refrigerant Line AR 82300102 R-134a Compressor Oil (PAG-ND8) AR 4797130 Coil, A/C Evaporator REPAIR PROCEDURE: This bulletin involves installing a different type of expansion valve, the addition of extra compressor lubricant and, if necessary, the A/C evaporator coil. **1. If the vehicle is a 1996 Model Year vehicle and contains the new expansion valve (P/N 5264744) and compressor (P/N 5264745) proceed to step 19.** 2. Recover the R-134a refrigerant while completely discharging the A/C system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Valve: > 240795A > Feb > 96 > A/C Evaporator - High Pitched Whistle > Page 5348 WARNING: THE A/C SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS OPERATION. 3. Remove the boot-type wire connector from the low pressure cut-off switch which is part of the expansion valve. 4. Remove the bolt in the center of the refrigerant line sealing plate. 5. Carefully pull the refrigerant line sealing plate from the expansion valve. 6. Cover the openings on refrigerant line sealing plate to prevent contamination or damage. 7. Remove the two screws attaching the expansion valve to the evaporator sealing plate. 8. Carefully remove the expansion valve and the two aluminum gaskets. Remove the Low Pressure Cut-off switch from the old expansion valve and install it on the **new expansion valve, P/N 5264744.** 9. Place a new gasket, PIN 4677045, on the evaporator sealing plate and install the ** new expansion valve, P/N 5264744.** DO NOT SCRATCH THE SEALING SURFACES of the new expansion valve. Install the two attaching screw and torque to 70 - 130 in. lbs (8 - 14 Nm). 10. Add two ounces of PAG-ND8, P/N 82300102, oil into the suction line. 11. Place a new gasket, P/N 3846834, on the refrigerant line sealing plate. 12. Carefully hold the refrigerant line sealing plate to the expansion valve, DO NOT SCRATCH THE SEALING SURFACES. Install the attaching bolt and torque to 170 - 230 in. lbs. (20 - 26 Nm.). 13. Connect the wire connectors to the low pressure cut-off switch. 14. Evacuate and recharge the A/C system. Proceed to the following steps to verify that the condition has been corrected. 15. The engine should be at normal operating temperature and the vehicle should be in a quiet location with all windows and doors closed. 16. Set the Heater-A/C controls to FLOOR, RECIRC, with the temperature control at "full heat" and blower on "high heat", A/C off. 17. Run the vehicle until the interior temperature reaches at least 110 degrees Fahrenheit. 18. Raise the engine speed to between 2,500 to 3,000 RPM and maintain. Switch the Heater-A/C blower control to "low A/C". 19. Listen for the condition to occur at the beginning of each A/C compressor clutch cycle. If the "whistle" is still exists replace the A/C evaporator coil, P/N 4797130 as outlined in the Service Manual, Pages 24-23 through 24-24. NOTE: USE NEW EXPANSION VALVE GASKETS PIN 4677045 AND 3846834 BUT DO NOT REPLACE THE EXPANSION VALVE A SECOND TIME. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE:Valve, A/C Expansion Valve, Replace & Add Oil Labor Operation No: 24-35-20-90 1.1 Hrs. Coil, Evaporator, Replace 24-65-02-96 4.0 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 5349 Expansion Valve: Description and Operation The expansion valve is used to meter refrigerant into the evaporator in accordance with cooling requirements. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 5350 Expansion Valve: Testing and Inspection NOTE: Expansion valve tests should be performed after compressor tests. NOTE: Liquid CO2 is required to test the expansion valve. It is available from most welding supply facilities. CO2 is also available from companies which service and sell fire extinguishers. WARNING: Review Safety Precautions and Warnings Before proceding. CAUTION: The work area and vehicle must be 21 ° to 27 °C (70 ° to 85 °F) when testing expansion valve. TO TEST THE EXPANSION VALVE: 1. Connect a charging station or manifold gauge set to the refrigerant system service ports. Low Pressure Cut Off Switch 2. Disconnect wire connector at low pressure cutoff switch. Using a jumper wire, jump terminals inside wire connector boot. 3. Close all doors, windows and vents to the passenger compartment. 4. Set Heater-A/C control to A/C, full heat, floor, RECIRC. and high blower. 5. Start the engine and hold the idle speed (1000 rpm). After the engine has reached running temperature, allow the passenger compartment to heat up. This will create the need for maximum refrigerant flow into the evaporator. 6. If the refrigerant charge is sufficient, discharge (high pressure) gauge should read 965 to 2620 kPa (140 to 380 psi). Suction (low pressure) gauge should read 103 to 2417 kPa (15 to 35 psi). If system cannot achieve proper pressure readings, replace the expansion valve. If pressure is correct, proceed with test. WARNING: Protect skin and eyes from contacting CO2, personal injury can result. 7. If suction side low pressure is within specified range, freeze the expansion valve control head for 30 seconds. Use a super cold substance (liquid C02). Do not spray refrigerant on the expansion valve for this test. Suction side low pressure should drop to 34.5 kPa (5 psi) If not, replace expansion valve. 8. Allow expansion valve to thaw. The low pressure gauge reading should stabilize at 103 to 241 kPa (15 to 35 psi). If not, replace expansion valve. 9. When expansion valve test is complete, test A/C overall performance. Refer to Testing and Inspection/Performance Test. Remove all test equipment before returning vehicle to use. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Technical Service Bulletins > Page 5351 Expansion Valve: Service and Repair WARNING: The refrigeration system must be completely empty before proceeding with this operation. REMOVAL 1. Remove the boot-type wire connector from the pressure cut-off switch. Expansion Valve 2. Remove the center bolt of refrigerant line plumbing sealing plate. 3. Carefully pull the refrigerant line-sealing plate assembly from the expansion valve towards front of vehicle. Do not scratch the expansion valve sealing surfaces with pilot tubes. 4. Cover the openings on A/C line-sealing plate assembly to prevent contamination. 5. Remove two screws securing the expansion valve to the evaporator sealing plate. 6. Carefully remove valve. INSTALLATION 1. Remove and replace the aluminum gasket on the evaporator sealing plate. 2. Carefully hold the expansion valve to the evaporator sealing plate so not to scratch the sealing surface. Install two screws and tighten to 8 to 14 N.m (70 to 130 in. lbs.). 3. Remove and replace the aluminum gasket on the refrigerant line- sealing plate assembly 4. Carefully hold the refrigerant line-sealing plate assembly to the expansion valve. Install bolt and tighten to 20 to 26 N.m (170 to 230 in. lbs.). 5. Connect wires to low pressure cut-off switch. 6. Evacuate and recharge system. 7. After expansion valve is installed, system is charged, and leaks have been checked, repeat A/C performance check. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair Heater Hose: Service and Repair CAUTION: When removing hoses from heater core inlet or outlet nipples DO NOT exert excess pressure. The heater core may become damaged and leak engine coolant. NOTE: Review Cooling System Precautions before proceeding with this operation. REMOVAL 1. Drain engine cooling system. 2. Remove clamp at end of heater hose to be removed. Heater Hose Quick Connect 3. ON Right Hand Drive (RHD) vehicles, heater hoses at the heater core connection have quick connects. The quick connect consist of two pieces; a quick connect and insert. The quick connect is removed by compressing the insert with a pliers, and pulling the quick connect free of the insert/nipple. Carefully compressed insert pulling the quick connect from connector nipple. The insert will remain on the connector nipple as the quick connect is removed. 4. Remove the heater hose clamp from the heater hose at the block and remove hose. INSTALLATION NOTE: The insert should be removed from the connector nipple and placed inside of the quick connect before reassembly. For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Locations High Pressure Safety Valve HVAC: Locations High Pressure Relief Valve The High Pressure Safety Valve is located on the compressor manifold. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Locations > Page 5358 High Pressure Safety Valve HVAC: Service and Repair WARNING: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved service equipment meeting sae requirements to discharge R-134a system. If accidental system discharge occurs, ventilate work area before resuming service. R-134a service equipment or vehicle A/C system should not be pressure tested or leak tested with compressed air. Mixtures of air and R-134a can be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion causing injury or property damage. REMOVAL 1. Using a R-134a refrigerant recovery machine, remove the refrigerant from A/C system. High Pressure Relief Valve 2. Rotate the high pressure relief valve counterclockwise and separate relief valve from the vehicle. INSTALLATION For installation, reverse the above procedures using a new 0-ring seal. Evacuate and charge the refrigerant system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation Hose/Line HVAC: Description and Operation DISCHARGE LINE Discharge Line The discharge line is the line that goes from the compressor to the condenser. It has no serviceable parts except the rubber 0-rings. If the line is found to be leaking or is damaged it must be replaced as an assembly. LIQUID LINE Liquid/Suction Line The liquid line is the line that goes from the condenser to the drier. It has no serviceable parts except the rubber 0-rings. If the line is found to be leaking or is damaged it must be replaced as an assembly. SUCTION LINE The suction line is the large line that connects to the expansion valve and goes to the compressor. It also has a small line that goes to the filter/ drier. The suction line uses a gasket on the expansion valve side and rubber 0-rings on all other connections. There are no serviceable parts on the suction line other than the rubber 0-rings and expansion valve gasket. If the line is found to be leaking or is damaged it must be replaced as an assembly. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Page 5362 Hose/Line HVAC: Service and Repair HANDLING TUBING AND FITTINGS Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and moisture can enter the system when it is opened for repair or replacement of lines or components. The refrigerant oil will absorb moisture readily out of the air. This moisture will convert to acids within a closed system. CAUTION: The system must be completely empty before opening any fitting or connection on the refrigerant system. Open fittings with caution even after system has been emptied. If pressure is noticed as a fitting is loosened, tighten fitting and evacuate system again. BENDING FLEX HOSE A good rule for the flexable hose lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharper bends will reduce the flow of the refrigerant. The flexible hose lines should be routed at least 3 inches away from exhaust manifolds. Inspect all flexible hose lines to make sure they are in good condition and properly routed. CAUTION: The use of correct wrenches when making connections is very important. Improper wrenches or the improper use of wrenches can damage the fittings. INTERNAL DAMAGE The internal parts of the A/C system will remain stable as long as moisture free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture, or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. OPENING SYSTEM When it is necessary to open the refrigeration system, have everything needed to service the system ready. The system should not be left open any longer than necessary. Cap or Plug all lines and fittings as soon as they are opened. This will prevent the entrance of dirt and moisture into the system. All new lines and components should be capped or sealed until they are ready to be used. CAUTION: All tools, including the refrigerant dispensing manifold, the manifold gauge set, and test hoses should be kept dry. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 241196 > Jul > 96 > A/C Unit - Air Whistle During Fresh Air Mode Housing Assembly HVAC: Customer Interest A/C Unit - Air Whistle During Fresh Air Mode NO.: 24-11-96 GROUP: Heater & A/C DATE: Jul. 12, 1996 SUBJECT: Air Whistle In A/C Unit During Fresh Mode And Higher Blower Speeds MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Some Neons may experience an air whistle at higher blower speeds with the fresh (outside) air setting. This is caused by an air leak between the air inlet housing and the inlet to the blower scroll cage. DIAGNOSIS: To verify condition, select fresh (outside) air and turn the blower control to the highest setting. With the glove box door removed (To remove door, see step 1 of Repair Procedure), push on the joint seam between the inlet housing and the top of the blower motor scroll cage (See Illustration). If the air whistle stops, proceed to the Repair Procedure. PARTS REQUIRED: AR NPN "Dum-Dum" Sealer (3M Strip Calk P/N 08578 or equivalent) REPAIR PROCEDURE: This bulletin involves sealing the joint seam between the air inlet housing and the inlet to the blower scroll. 1. With the glove box door open, remove the door by pushing on the ends of the box to allow the bumpers to clear the instrument panel surface. 2. Using the "Dum-Dum" sealer, seal the area shown in the illustration. Make sure that the joint seam is completely sealed. 3. Install the glove box door. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 241196 > Jul > 96 > A/C Unit - Air Whistle During Fresh Air Mode > Page 5371 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-32-92 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 241196 > Jul > 96 > A/C Unit Air Whistle During Fresh Air Mode Housing Assembly HVAC: All Technical Service Bulletins A/C Unit - Air Whistle During Fresh Air Mode NO.: 24-11-96 GROUP: Heater & A/C DATE: Jul. 12, 1996 SUBJECT: Air Whistle In A/C Unit During Fresh Mode And Higher Blower Speeds MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Some Neons may experience an air whistle at higher blower speeds with the fresh (outside) air setting. This is caused by an air leak between the air inlet housing and the inlet to the blower scroll cage. DIAGNOSIS: To verify condition, select fresh (outside) air and turn the blower control to the highest setting. With the glove box door removed (To remove door, see step 1 of Repair Procedure), push on the joint seam between the inlet housing and the top of the blower motor scroll cage (See Illustration). If the air whistle stops, proceed to the Repair Procedure. PARTS REQUIRED: AR NPN "Dum-Dum" Sealer (3M Strip Calk P/N 08578 or equivalent) REPAIR PROCEDURE: This bulletin involves sealing the joint seam between the air inlet housing and the inlet to the blower scroll. 1. With the glove box door open, remove the door by pushing on the ends of the box to allow the bumpers to clear the instrument panel surface. 2. Using the "Dum-Dum" sealer, seal the area shown in the illustration. Make sure that the joint seam is completely sealed. 3. Install the glove box door. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 241196 > Jul > 96 > A/C Unit Air Whistle During Fresh Air Mode > Page 5377 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-32-92 0.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly Housing Assembly HVAC: Service and Repair Evaporator Housing Disassembly and Assembly Use this procedure if any or all of the following items require service: - Heater core - Temperature door - Mode door - Heat/Defrost door - Assembly housing The unit housing must be removed from the vehicle before beginning with this procedure. DISASSEMBLE For Right Hand Drive (RHD) vehicles, the Unit Housing does not separate. It is a one piece unit and must be replaced as a whole. Air Distribution Module Separation 1. Remove the clips and screws that hold the Air Distribution Module to the Evaporator/Blower Module. Then separate the two units. 2. Remove the panel opening foam seal, demister opening foam seal, and heater core tube foam seals from unit. Retaining Clip Removal 3. Remove the retaining clips and screws that hold the upper and lower housings together. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5380 Case Separation 4. Place the unit in the upside down position. Then separate the two halves of the module. Heater Core Removal 5. Lift the heater core out of the case. Temperature Door Removal 6. Press tab in at base of temperature door and release door from lever. Then remove the door. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5381 Mode Door Removal 7. Press tab in at base of mode door and release door from lever. Cam Screw Removal 8. Remove Heat/Defrost door cam screw. Cam And Lever Removal 9. Lift the cam and mode door lever off of the housing. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5382 Pivot Screw Removal 10. Remove the Heat/Defrost link pivot screw. 11. Lift the Heat/Defrost link and the door as an assembly. Then separate the link from the door. ASSEMBLE To reassemble, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5383 Housing Assembly HVAC: Service and Repair Heater - A/C Housing Removal and Installation The instrument panel must be removed in order to remove the Unit Housing. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" WARNING: THE R-134a REFRIGERANT SYSTEM MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEM. REMOVAL 1. Remove instrument panel from vehicle. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" . 2. Drain cooling system and remove heater hoses at the dash panel. Place plugs in the heater core outlets to prevent coolant spillage during unit housing removal. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" 3. Using a refrigerant recovery machine, remove the refrigerant from the A/C system, if equipped. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair 4. Remove suction line at expansion valve. Place a piece of tape over open refrigerant line to prevent moisture and/or dirt from entering the line. 5. Remove expansion valve from evaporator. Place a piece of tape over open evaporator fitting to prevent moisture and/or dirt from entering the evaporator. 6. Remove rubber drain tube extension from condensation drain tube. Dash Panel Studs 7. Remove three retaining nuts located in the engine compartment, on the dash panel. Retaining Screws 8. Remove the right side retaining screw. 9. Remove remaining nut located on dash panel stud. 10. Disconnect the blue five way connector from the plenum. Module wiring harness must be removed with module. 11. Remove assembly from the vehicle. For HVAC Unit Housing Disassembly and Assembly, refer to: "Evaporator Core : Service and Repair" See: Evaporator Core/Service and Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 5384 INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair Receiver Dryer: Service and Repair The filter/drier is mounted in a rubber grommet on the right side of the engine compartment. The refrigerant must be recovered from the A/C system before replacing the filter/drier assembly. WARNING: The refrigeration system must be completely recovered before proceeding with this operation. REMOVAL 1. Disconnect liquid line from filter/drier. 2. Disconnect liquid line on suction line assembly from filter/drier. 3. Pull filter/drier out of rubber grommet. INSTALLATION For installation reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications Refrigerant: Specifications A/C Refrigerant Specifications A/C Refrigerant Specifications Refrigerant Capacity 1.75 lb (US) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications Refrigerant Oil: Specifications Fluid Specifications Fluid Specifications Ounces Viscosity 4.75 oz (US) ND8 PAG Polyalkaline Glycol Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 5394 Refrigerant Oil: Service and Repair It is important to have the correct amount of oil in the A/C system to ensure proper lubrication of the compressor. Too little oil will result in damage to the compressor. Too much oil will reduce the cooling capacity of the system and consequently result in higher discharge air temperatures. NOTE: The oil used in the compressor is ND8 PAG R-134a refrigerant oil. Only refrigerant oil of the same type should be used to service the system. Do not use any other oil. The oil container should be kept tightly capped until it is ready for use. Tightly cap afterwards to prevent contamination from dirt and moisture. Refrigerant oil will quickly absorb any moisture it comes in contact with. Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. It will not be necessary to check oil level in the compressor or to add oil unless there has been an oil loss. Oil loss at a leak point will be evident by the presence of a wet, shiny surface around the leak. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations High Pressure Cut Out Switch The high pressure cut out switch is located in the compressor manifold. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5399 High Pressure Sensor / Switch: Description and Operation HIGH PRESSURE CUT-OFF SWITCH The High Pressure Cut-Off Switch turns off the compressor if the system pressure exceeds 3240 kPa (470 psi). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5400 High Pressure Sensor / Switch: Service and Repair WARNING: The refrigerant must be removed from the system before removing the high pressure cut out switch. REMOVAL High Pressure Relief Valve 1. Disconnect wiring connector at the switch. 2. Remove internal snap ring. 3. Pull switch out of manifold. INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Low Pressure Sensor / Switch: Locations Low Pressure Cut Off Switch The low pressure cut off switch is located on the expansion valve. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5404 Low Pressure Sensor / Switch: Description and Operation LOW PRESSURE CUT-OFF SWITCH The Low Pressure Cut Off Switch monitors the refrigerant gas pressure on the suction side of the system. It turns off voltage to the compressor clutch coil when refrigerant gas pressure drops to levels that could damage the compressor. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5405 Low Pressure Sensor / Switch: Testing and Inspection CAUTION: The work area must not be below 21°C (70°F) to test the compressor clutch circuit. 1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Raise hood and disconnect low pressure cut off switch connector boot. 3. Using a suitable jumper wire, jump across the terminals inside wire connector boot. 4. If the compressor clutch does not engage, the cycling clutch switch, wiring, relay, or fuse can be defective. 5. If clutch engages, connect manifold gauge set. Read low pressure gauge. At pressure above 97 kPa (14 psi) and above, low pressure out off switch will complete the clutch circuit. If the low pressure gauge reads below 140 kPa (20 psi), the system is low on refrigerant charge or empty due to a leak. 6. Install connector boot on switch and repeat Step 3. If the clutch does not engage, replace the low pressure cut off switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5406 Low Pressure Sensor / Switch: Service and Repair The low pressure cut out switch is a sealed factory calibrated unit. It must be replaced if defective. WARNING: The refrigeration system must be completely recovered before proceeding with this operation. REMOVAL 1. Disconnect the boot like wire connector at the cut off switch. Low Pressure Cut Off Switch 2. Using a sender unit removal socket, remove the switch from the expansion valve. INSTALLATION NOTE: Verity the 0-ring condition on the replacement switch. For installation, reverse the above procedures. Evacuate and charge the system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Power Distribution (Part 1 Of 2) Fig. 15 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Fig.31 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 5414 Power Distribution Center (Top) The Power Distribution Center (PDC) The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay, A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 5415 Solid State Relay Solid State Relay Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 5416 Condenser Fan Motor Relay: Description and Operation Radiator Fan Relay-PCM Output The PCM energizes the radiator fan through the radiator fan relay. The PCM controls the ground circuit for the solenoid side of the relay. Buss bars in the Power Distribution Center (PDC) supply voltage to the solenoid side and contact side of the relay. The radiator fan power circuit contains a 30 amp fuse between the buss bar in the PDC and the radiator fan relay. The fuse is located in the PDC. When engine coolant reaches a temperature of 99°C (210°F), the PCM energizes the radiator fan. The PCM turns the fan OFF when coolant temperature drops to 93°C (199°F). Whenever the PCM energizes the A/C compressor clutch it engages the fan. Also, to prevent radiator steaming, the PCM energizes the radiator fan at idle following certain cold starts. The radiator fan relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Radiator Fan Relay/Diagrams/Connector Views Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Locations Evaporator Temperature Sensor/Clutch Cycling Switch: Locations Evaporator Probe Location The evaporator probe is located in the Evaporator Case unit housing and placed in the evaporator fins. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions Evaporator Temperature Sensor/Clutch Cycling Switch: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5423 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5424 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5425 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5426 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5427 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5428 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5429 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5430 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5431 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5432 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5433 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5434 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5435 Evaporator Temperature Sensor/Clutch Cycling Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5436 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 5437 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 5438 Evaporator Temperature Sensor/Clutch Cycling Switch: Description and Operation EVAPORATOR PROBE The evaporator probe can be replaced without having to remove the unit housing from the vehicle. The evaporator probe is located in the unit housing and placed in the evaporator fins. the probe prevents evaporator freeze-up. This is done by cycling the compressor clutch OFF when evaporator temperature rises above freeze point. It cycles ON when the evaporator temperature rises above freeze point. The evaporator probe uses a thermistor probe in a capillary tube. The tube is inserted between the evaporator fins in the heater-A/C unit housing. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 5439 Evaporator Temperature Sensor/Clutch Cycling Switch: Testing and Inspection CAUTION: The work area and vehicle must be between 16° C (60° F) and 32° C (90° F) when testing the switch. 1. Disconnect the three wire connector from the evaporator probe lead located behind the glove box. 2. Start engine and set A/C to low blower motor speed, panel, full cool, and RECIRC. Evaporator Probe Harness Connector 3. Using a voltmeter, check for battery voltage between Pin 1 and 2. If no voltage is detected, there is no power to the switch. Check wiring and fuses. 4. Using a voltmeter, check for battery voltage between Pin 1 and Pin 3. If no voltage is detected, there is no voltage from the Powertrain Control Module. If voltage is OK, connect a jumper wire between Pin 1 and Pin 3. The compressor clutch should engage. If the clutch engages, remove the jumper wire immediately and go to Step 5. If the compressor clutch does not engage, check the operation of the clutch and repair as necessary. 5. If compressor clutch engages, connect the evaporator probe 3-way connector. The compressor clutch should engage or cycle depending on evaporator temperature. If OK, go to Step 6. If not OK, replace the clutch cycling switch. 6. The engine running and the A/C set to: - Blower motor on low speed - Panel position - Full cool - RECIRC. - Close all doors and windows. Place a thermometer in the center discharge vent. 7. If the clutch does not begin to cycle off between 2° C to 7° C (35° F to 45° F), verify that the evaporator probe is fully installed and not loose in evaporator. If it is not properly installed, install probe and reset outlet temperature. If the evaporator probe is properly installed, replace the clutch cycling switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Diagrams > Page 5440 Evaporator Temperature Sensor/Clutch Cycling Switch: Service and Repair REMOVAL NOTE: The evaporator probe can be replaced without having to remove the unit housing from the vehicle. 1. Disconnect probe wiring connector from behind the glove box. Evaporator Probe Location 2. Remove rubber grommet from evaporator blower module. 3. Note in which of the three pilot holes the evaporator probe is located. 4. Pull probe out of evaporator fins. INSTALLATION 1. There are three pilot holes available for the probe. The top hole is for service. If top hole was not used by previous probe, install probe in top hole. 2. If previous probe was removed from top hole, use a small plastic stick and make a new hole. Make the hole 1/4 inch above or below the original hole in the evaporator core. 3. Insert new probe into hole between evaporator fins. 4. Reinstall rubber grommet into evaporator probe access hole. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations High Pressure Cut Out Switch The high pressure cut out switch is located in the compressor manifold. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5445 High Pressure Sensor / Switch: Description and Operation HIGH PRESSURE CUT-OFF SWITCH The High Pressure Cut-Off Switch turns off the compressor if the system pressure exceeds 3240 kPa (470 psi). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5446 High Pressure Sensor / Switch: Service and Repair WARNING: The refrigerant must be removed from the system before removing the high pressure cut out switch. REMOVAL High Pressure Relief Valve 1. Disconnect wiring connector at the switch. 2. Remove internal snap ring. 3. Pull switch out of manifold. INSTALLATION For installation, reverse the above procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Low Pressure Sensor / Switch: Locations Low Pressure Cut Off Switch The low pressure cut off switch is located on the expansion valve. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5450 Low Pressure Sensor / Switch: Description and Operation LOW PRESSURE CUT-OFF SWITCH The Low Pressure Cut Off Switch monitors the refrigerant gas pressure on the suction side of the system. It turns off voltage to the compressor clutch coil when refrigerant gas pressure drops to levels that could damage the compressor. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5451 Low Pressure Sensor / Switch: Testing and Inspection CAUTION: The work area must not be below 21°C (70°F) to test the compressor clutch circuit. 1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Raise hood and disconnect low pressure cut off switch connector boot. 3. Using a suitable jumper wire, jump across the terminals inside wire connector boot. 4. If the compressor clutch does not engage, the cycling clutch switch, wiring, relay, or fuse can be defective. 5. If clutch engages, connect manifold gauge set. Read low pressure gauge. At pressure above 97 kPa (14 psi) and above, low pressure out off switch will complete the clutch circuit. If the low pressure gauge reads below 140 kPa (20 psi), the system is low on refrigerant charge or empty due to a leak. 6. Install connector boot on switch and repeat Step 3. If the clutch does not engage, replace the low pressure cut off switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5452 Low Pressure Sensor / Switch: Service and Repair The low pressure cut out switch is a sealed factory calibrated unit. It must be replaced if defective. WARNING: The refrigeration system must be completely recovered before proceeding with this operation. REMOVAL 1. Disconnect the boot like wire connector at the cut off switch. Low Pressure Cut Off Switch 2. Using a sender unit removal socket, remove the switch from the expansion valve. INSTALLATION NOTE: Verity the 0-ring condition on the replacement switch. For installation, reverse the above procedures. Evacuate and charge the system. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations High Side Service Port The high side service port is located on the filter drier. Low Side Service Port Valve (in Suction Line) The low side service port is located on the suction line. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 5456 Service Port HVAC: Service and Repair REMOVAL High Side Service Port Low Side Service Port Valve (in Suction Line) 1. Remove the valve caps. 2. Using a R-134a refrigerant recovery machine, Remove the refrigerant from A/C system. 3. Using a standard valve core tool, remove the valve core. Be careful to prevent any dirt/debris from entering the valve core opening or getting on the replacement valve core. INSTALLATION 1. When assembling the new valve core into the port, the core should be oiled with clean ND8 PAG compressor oil. CAUTION: A valve that is not fully seated can lead to damage to the valve during evacuation and charge. This can result in system refrigerant discharge while uncoupling the charge adapters. 2. Install valve core into port. 3. Evacuate and charge the A/C system. 4. Install the valve caps. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 WARNINGS: - 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. - 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, use proper and safe service procedures . Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: 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 disarm the system. NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). 1. Disconnect and isolate the battery negative (ground) cable. 2. 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 air-bag deployment and possible personal injury. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 5464 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming WARNING: Before attempting to diagnose, remove or install any airbag system components, first disconnect and isolate battery ground cable, then wait at least 2 minutes prior the performing any service. - Failure to do so may result in airbag deployment or personal injury. 1. Connect the scan tool to the Data Link connector which is located on the left side kick panel just above the hood release. 2. Turn the ignition key to the ON position. Exit vehicle with the scan tool. Use the latest version of the diagnostic cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative remote terminal. 4. Using the scan tool, read and record the active diagnostic trouble code data. 5. Read and record any stored diagnostic trouble codes. 6. Refer to Powertrain Management/Computers and Controls/Body Control Module if any diagnostic trouble codes are found in Step 4 and Step 5. 7. Erase stored diagnostic trouble codes if there are no active diagnostic trouble codes. If problems remain, diagnostic trouble codes will not erase. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. If the airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 5469 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 5470 Air Bag: Technical Service Bulletins Air Bag Replacement - Control Module Requirements NO: 08-04-96 GROUP: Electrical DATE: Feb. 9, 1996 SUBJECT: Air Bag Replacement - Control Module Requirements MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL 1996 NEON VEHICLES BUILT PRIOR TO 01-02-96 (MDH O1-02-xx). DISCUSSION: When replacing a passenger side airbag on 1996 Neon vehicles built prior to January 2, 1996, the airbag control module must also be replaced using P/N 5269907. If the control module is not replaced, the airbag warning light will illuminate when the ignition is turned on following service. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 5471 Airbag Module (Driver) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 5472 Air Bag: Diagrams Driver Squib Connector Passenger Squib Connector Passenger Airbag Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 5473 Air Bag: Description and Operation Fig. 1 Driver Airbag WARNING: Never disassemble the driver or passenger airbag module, there are no serviceable parts within the module. DRIVER SIDE The driver airbag module located on the steering wheel is the most visible part of the system. It contains the airbag cushion and its supporting components. The airbag module contains a housing to which the cushion and inflator are attached and sealed. The driver side inflator assembly is mounted from the back of the module housing. When supplied with the proper electrical signal the inflator assembly will produce a gas and discharge it directly into the cushion. A protective cover is fitted to the front of the driver airbag module and forms a decorative cover in the center of the steering wheel. The driver airbag module is mounted directly to the steering wheel. Fig. 2 Passenger Airbag PASSENGER SIDE The passenger airbag module is located beneath the decorative cover of the instrument panel, facing the passenger seat. The passenger inflator assembly is contained in the airbag module housing. The airbag module housing is mounted to the instrument panel retainer, knee bolster and glove box. When supplied with the proper electrical signal the inflator produces a gas and discharges it directly into the cushion. A decorative, protective cover is fitted over the airbag module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures Air Bag: Service and Repair Air Bag Module Disposal Procedures After deployment, air bag module should be placed in a plastic bag and disposed of in same manner as any other scrap parts, except that following points should be carefully noted during disposal. 1. When handling deployed air bag assembly, face shield and rubber gloves should be worn. 2. There may be, adhered to air bag module, material that could irritate eyes and/or skin. Note: If any irritation develops, seek medical attention. a. If sinus or throat irritation is encountered during air bag removal, exit vehicle and breath fresh air. b. If material does come in contact with eyes and/or skin, immediately rinse affected area with a large amount of cool, clean water. c. If sinus, throat, skin or any other type of irritation continues, consult a physician. 3. After handling a deployed air bag assembly, wash hands and rinse thoroughly with water. 4. CAUTION: Inflator will be quite hot immediately after deployment, wait 30 minutes to allow air bag to cool. 5. Do not put water or oil on air bag after deployment. 6. Put deployed air bag in a hermetically sealed container and discard it. 7. Use a vacuum cleaner to remove any residual powder from vehicle interior as follows: a. Work from outside to center of vehicle. b. Vacuum A/C, vent, defroster and heater ducts. c. Run blower motor on low speed and vacuum any powder expelled from plenum. d. It may be necessary to vacuum interior of vehicle a second time to ensure all powder is recovered. 8. An air bag that has been deployed should be removed as described under Airbag Module Replacement. 9. Prior to removing a deployed air bag assembly, place tape over air bag exhaust vents. 10. Before disposing of a vehicle equipped with air bag(s), or prior to disposing of air bag module, module must be deployed as follows: a. If vehicle is to be scrapped, deploy air bag(s) inside vehicle. b. If vehicle is to continue in service, air bags must be removed and deployed outside vehicle. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 5476 Air Bag: Service and Repair Driver Side Airbag Module Replacement Fig. 6 Driver Airbag Module 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. WARNING: When vehicle is involved in an impact great enough to deploy the airbag modules, the steering coupler will have to be replaced. WARNING: Replace airbag system components with Chrysler Mopar (R) specified replacement parts. Substitute parts may visually appear interchangeable, but internal differences may result in inferior occupant protection. WARNING: When removing a deployed module, rubber gloves, eye protection and long sleeve shirt should be worn, as there may be deposits on the surface which could irritate the skin and eyes. DEPLOYED MODULE The vehicle interior may contain a very small amount of sodium hydroxide powder, a by-product of airbag deployment. Since this powder can irritate the skin, eyes, nose or throat, be sure to wear safety glasses, rubber gloves and long sleeves during cleanup. If you find that the cleanup is irritating your skin, run cool water over the affected area. Also, if you experience nasal or throat irritation, exit the vehicle for fresh air until the irritation ceases. If irritation continues, see a physician. SERVICE OF DEPLOYED AIRBAG MODULE After a DRIVER airbag has been deployed, the airbag module and clockspring assembly must be replaced because they cannot be reused. Other driver airbag system components are replaced if damaged. Fig. 4 Wear Safety Glasses And Gloves CLEAN UP Wear safety glasses, rubber gloves, particle dust mask and protective clothing with long sleeves. Place tape over exhaust vents in air bag so that no additional powder will escape into vehicle. Roll or fold passenger's air bag toward instrument panel surface and close cover over folded air bag. Tape cover closed. Remove driver's air bag module from vehicle then passenger's air bag module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 5477 Fig. 5 Vacuum Heater And A/C Outlets Use a vacuum cleaner to remove any residual powder from vehicle interior working from outside to center of vehicle. Be sure to vacuum heater and A/C ducts as well. Run blower motor on low speed and vacuum any powder expelled from plenum. It may be necessary to vacuum interior of vehicle a second time to ensure all powder is recovered. REPLACEMENT 1. Disconnect and isolate the battery negative cable. 2. Remove speed control switches or covers from steering wheel back shroud and disconnect the wires. 3. Remove two bolts attaching airbag module from the sides of steering wheel. 4. Lift module and disconnect airbag squib wire connector. 5. Remove driver airbag module. 6. When replacing a deployed driver airbag module, the clockspring must also be replaced. Refer to Clockspring Removal and Installation for proper procedure. 7. For installation, reverse above procedures. a. Connect the squib wire to the module. Make airbag connection by pressing straight in on the connector. The connector should be fully seated feel for positive snap to assure positive connection. b. Install two bolts and tighten to 10 to 11 Nm (90 to 100 in lb) torque. c. Install covers to the steering wheel back shroud or connect the wire connectors to the speed control switches and install switches. Tighten fastener to 2 Nm (20 in lb). d. Do not connect battery negative cable. Refer to Airbag System Check for proper procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 5478 Air Bag: Service and Repair Passenger Side Airbag Module Replacement Deployed Module Fig. 7 Remove Or Install Battery Cable WARNING: When removing a deployed module, rubber gloves, eye protection, and a long-sleeved shirt should be worn, as there may be deposits on the surface which could irritate the skin and eyes. WARNING: When vehicle is involved in an impact great enough to deploy the airbag modules, the steering coupler will have to be replaced. WARNING: Replace airbag system components with Chrysler Mopar (R) specified replacement parts. Substitute parts may visually appear interchangeable, but internal differences may result in inferior occupant protection. DEPLOYED MODULE The vehicle interior may contain a very small amount of sodium hydroxide powder, a by-product of airbag deployment. Since this powder can irritate the skin, eyes, nose or throat, be sure to wear safety glasses, rubber gloves and long sleeves during cleanup. If you find that the cleanup is irritating your skin, run cool water over the affected area. Also, if you experience nasal or throat irritation, exit the vehicle for fresh air until the irritation ceases. If irritation continues, see a physician. SERVICE OF DEPLOYED AIRBAG MODULE After a PASSENGER airbag has been deployed, the passenger airbag module must be replaced because it cannot be reused. Other components are replaced if damaged. These might include the trim bezel, top cover or the entire instrument panel. Fig. 4 Wear Safety Glasses And Gloves CLEAN UP Wear safety glasses, rubber gloves, particle dust mask and protective clothing with long sleeves. Place tape over exhaust vents in air bag so that no additional powder will escape into vehicle. Roll or fold passenger's air bag toward instrument panel surface and close cover over folded air bag. Tape cover closed. Remove driver's air bag module from vehicle then passenger's air bag module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 5479 Fig. 5 Vacuum Heater And A/C Outlets Use a vacuum cleaner to remove any residual powder from vehicle interior working from outside to center of vehicle. Be sure to vacuum heater and A/C ducts as well. Run blower motor on low speed and vacuum any powder expelled from plenum. It may be necessary to vacuum interior of vehicle a second time to ensure all powder is recovered. REPLACEMENT 1. Disconnect and isolate the battery negative cable. 2. Roll/fold airbag towards instrument panel. 3. Close door over folded airbag and tape door closed. Fig. 8 Instrument Panel 4. Remove instrument panel top cover. 5. Remove instrument panel right trim panel. 6. Open glove box and push the sides inward allowing the door bumper to pass and box to open. Fig. 9 Passenger Airbag Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 5480 7. Remove the four trim screws which attach the module to the top instrument panel. 8. Remove two module attaching nuts from the support structure. 9. Lift module up until the electrical connector is visible and disconnect the connector from module. 10. For installation, reverse above procedures. - Tighten trim screws to 2 Nm (20 in lb) torque. - Tighten the module nuts to 22 to 34 Nm (200 to 300 in lb) torque. Undeployed Module Fig. 7 Remove Or Install Battery Cable NOTE: Use this procedure when removing a module for any reason other than DEPLOYMENT. 1. Disconnect and isolate the battery negative cable. Fig. 8 Instrument Panel 2. Remove instrument panel top cover. 3. Remove instrument panel right trim bezel. 4. Open glove box and push the sides inward allowing the door bumper to pass and box to open. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Module Disposal Procedures > Page 5481 Fig. 9 Passenger Airbag Module 5. Remove the four trim screws which attach the passenger airbag module to the top instrument panel. 6. Remove two module attaching nuts from the support structure. 7. Lift module up until the electrical connector is visible and disconnect the connector from module. 8. For installation, reverse above procedures. - Tighten trim screws to 2 Nm (20 in lb) torque. - Tighten the module nuts to 22 to 34 Nm (200 to 300 in lb) torque. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Air Bag Replacement - Control Module Requirements Air Bag Control Module: Technical Service Bulletins Air Bag Replacement - Control Module Requirements NO: 08-04-96 GROUP: Electrical DATE: Feb. 9, 1996 SUBJECT: Air Bag Replacement - Control Module Requirements MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL 1996 NEON VEHICLES BUILT PRIOR TO 01-02-96 (MDH O1-02-xx). DISCUSSION: When replacing a passenger side airbag on 1996 Neon vehicles built prior to January 2, 1996, the airbag control module must also be replaced using P/N 5269907. If the control module is not replaced, the airbag warning light will illuminate when the ignition is turned on following service. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5486 Air Bag Control Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5487 Air Bag Control Module: Diagrams Airbag Control Module Connector -- 13 Way Airbag Control Module Connector -- 4 Way Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5488 Air Bag Control Module: Description and Operation OPERATION The ACM/Air Bag System Diagnostic Module (ASDM) contains safing sensor and energy reserve capacitor, while the ACM/Air Bag Electronic Control Module (AECM) contains impact sensor and energy reserve capacitor. The ACM monitors system to determine system readiness. The ACM will store sufficient energy to deploy air bag for two minutes after battery has been disconnected. The ACM contains an on board diagnostics function that will illuminate air bag warning lamp when a system fault occurs. CIRCUIT OPERATION Two different circuits supply battery voltage from the fuse block to the Airbag Control Module (ACM), F15 and F25. The F15 and F25 circuits are connected to separate bus bars internal to the fuse block. Different circuits from the Power Distribution Center (PDC) and ignition switch supply battery voltage to the fuse block bus bars. The F25 circuit supplies battery voltage to the ACM only when the ignition switch is in the RUN position. The F15 circuit powers the ACM when the ignition switch is in either the START or RUN position. An internal bus bar in the ignition switch connects the A1 circuit from the PDC to the A21 circuit when the switch is either the START or RUN position. The A21 circuit supplies battery voltage to the bus bar in the fuse block that feeds the F15 circuit. A 30 Amp fuse in the PDC protects the A1 and A21 circuits. A 10 Amp fuse in the fuse block, cavity 9, protects the F15 circuit. When the ignition switch is in the RUN position, it connects the A2 circuit from the PDC to the A22 circuit. The A22 circuit supplies battery voltage to the fuse block bus bar that feeds the F25 circuit. A 40 Amp fuse in the PDC protects the A2 and A22 circuits. A 10 Amp fuse in the fuse block, cavity 5, protects the F25 circuit. The ACM has a case ground and an external dedicated ground, circuit Z6. The dedicated ground connects to the instrument panel right center support. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5489 Air Bag Control Module: Service and Repair WARNING: The ACM contains a safing sensor which enables the system to deploy the airbags. To avoid accidental deployment, never connect ACM electrically to the system while vehicle battery is connected. Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components. CAUTION: Failure to follow the parking brake service procedures can result in damage to the parking brake mechanism. WARNING: The auto adjusting feature of this parking brake lever assembly contains a clock spring loaded to approximately 20 pounds. DO NOT release the auto adjuster lockout device before installing cables into the equalizer. Keep hands out of auto adjuster sector and pawl area. Failure to observe caution in handling this mechanism could lead to serious injury. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Manual transaxle only, remove shifter knob fastener and remove shifter knob. Fig 6 Attaching Screws At Rear Of Center Console With/Without Arm Rest Fig 7 Attaching Screws At Rear Of Center Console With Arm Rest 3. Remove screws attaching rear of center console assembly to console bracket. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5490 Fig 8 Attaching Screws At Front Of Center Console 4. Remove the two screws located in cup holders, attaching front of center console assembly to console bracket. 5. Raise park brake hand lever assembly as high as it will go for required clearance to remove center console. 6. Remove center console assembly from vehicle. WARNING: When repairs to the park brake hand lever assembly or cables is required, the auto adjuster must be reloaded and locked out. 7. Lower park brake lever handle. Fig 9 Locking Pin Installed In Park Brake Mechanism 8. Grasp park brake lever output cable by hand and pull upward. - Continue pulling on cable until a 3/16 in. drill bit can be inserted into handle and sector gear of park brake mechanism. - This will lock the park brake mechanism and take tension off park brake cables. Fig 10 Removing Park Brake Cables From Equalizer Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5491 9. Remove both rear park brake cables from the park brake cable equalizer. Fig 11 Brake Warning Lamp Connection To Park Brake Lever 10. Remove wiring harness electrical connector for brake warning light from park brake lever. Fig 12 Park Brake Lever Attachment To Console Bracket 11. Remove the two nuts attaching park brake lever to console bracket. Remove park brake lever mechanism from vehicle. Fig 13 Airbag Control Module 12. Remove module mounting nuts and remove module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5492 Fig 14 ACM Connectors 13. Disconnect ACM 4-way and 13-way connectors. 14. Remove Airbag Control Module. INSTALLATION 1. Connect both ACM connectors and ensure both connectors and all locking tabs are engaged. CAUTION: USE SUPPLIED SCREWS ONLY. 2. Position ACM (arrow pointing forward) in the console floor bracket, attach the nuts and tighten to 11 to 14 Nm (105 to 125 in lb) torque. NOTE: The park brake lever can be in any position when releasing the auto adjuster. To ease installation of center console, it is advisable to pull park brake lever handle all the way up before removing lockout pin. 3. Place park brake lever on console bracket. - Install and securely tighten the 2 attaching nuts. Fig 15 Park Brake Cables Properly Installed In Equalizer Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5493 Fig 16 Rear Park Brake Cable Installation On Equalizer 4. Install both rear park brake cables into equalizer on park brake lever output cable. 5. Ensure that park brake cable is correctly installed and aligned with cable track on park brake lever. 6. Pull park brake lever handle all the way up. Fig 17 Removing Lockout Pin From Park Brake Lever Assembly 7. Firmly grasp park brake lever locking pin and quickly remove it from the park brake lever mechanism. This will allow the park brake lever mechanism to correctly adjust the park brake cables. Fig 18 Brake Warning Lamp Connection To Park Brake Lever 8. Connect electrical connector for brake warning lamp onto terminal on park brake lever assembly. 9. Cycle park brake lever once to position park brake cables. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5494 - Then return the park brake lever its released position. - Check the rear wheels of the vehicle -- they should rotate freely without dragging. 10. Raise park brake lever to its fully engaged position. - This is necessary to allow installation of the center console. 11. Install center console assembly Fig 19 Attaching Screws At Rear Of Center Console With/without Arm Rest Fig 20 Attaching Screws At Rear Of Center Console With Arm Rest Fig 21 Attaching Screws At Front Of Center Console 12. Install the four center console assembly attaching screws. 13. Replace shifter knob and fastener. 14. Do not connect battery negative cable. Refer to Airbag System Check for proper procedure. See: Testing and Inspection Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5499 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5500 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5501 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5502 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5503 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5504 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5505 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5506 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5507 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5508 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5509 PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5510 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5511 POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service Clockspring Assembly / Spiral Cable: Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 5516 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Component Locations Clockspring Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Component Locations > Page 5519 Clockspring Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 5520 Clockspring Assembly / Spiral Cable: Diagrams Clockspring Connector -- 2 Way Speed Control Switch Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 5521 Clockspring Assembly / Spiral Cable: Description and Operation PURPOSE The clockspring, mounted on the steering wheel column, behind the steering wheel, is used to maintain a continuous electrical circuit between the wiring harness and the: Driver's airbag module. - Speed control switches. - Horn switches. CONSTRUCTION The clockspring assembly consists of a flat, ribbon like, electrically conductive tape, which winds and unwinds as the steering wheel is rotated. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 5522 Clockspring Assembly / Spiral Cable: Adjustments CLOCKSPRING CENTERING PROCEDURE 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. 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. Remove clockspring, refer to Clockspring Removal. 2. Rotate the clockspring rotor in the CLOCKWISE DIRECTION to the end of travel. Do not apply excessive torque. 3. From the end of travel, rotate the rotor two full turns and a half in the counterclockwise direction. The horn wire and the squib wire should end up at the bottom. If not, rotate the rotor counter clockwise until the wires are properly orientated, but not more than half turn (180 degrees). Engage clockspring locking mechanism. 4. For installation, refer to Clockspring Assembly/Spiral Cable/Service and Repair. 5. Do not connect battery negative cable. Refer to Testing and Inspection/Procedures for Airbag System Test procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 5523 Clockspring Assembly / Spiral Cable: Service and Repair REMOVAL WARNING: Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components. 1. Place the front road wheels in the straight ahead position then: - Rotate the steering wheel half turn (180 degrees) to the right (clockwise) - Lock column with ignition lock cylinder. 2. Disconnect and isolate the battery negative cable. 3. Wait two minutes for the reserve capacitor to discharge before removing non-deployed module. 4. Remove speed control switch mounting screws, switches and disconnect the wire connectors or remove covers. 5. Remove the Driver Airbag Module attaching bolts from under the speed control switches or covers. 6. Lift module and disconnect the airbag and horn wire connectors. 7. Remove the steering wheel. 8. Remove upper and lower steering column shrouds to gain access to clockspring wiring. 9. Disconnect the 2-way and 4-way connectors between the clockspring and the instrument panel wiring harness at the base of the clockspring. 10. Unlatch and remove clockspring assembly from steering shaft. The clockspring cannot be repaired, and must be replaced if faulty 11. Rotate clockspring rotor a half turn (180 degrees) to the left (counter clockwise). 12. Lock the clockspring rotor in the center position as follows: Insert a paper clip wire through the hole in the rotor at the 10 O'clock position and bend to prevent it from falling out. INSTALLATION 1. Confirm that: - The steering wheel position is a half turn (180 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 steering column shrouds. Be sure all wires are inside of shrouds. 4. 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. 5. Route speed control wires under and behind the airbag module mounting tabs. 6. Connect the horn lead wire and the airbag lead wire to the airbag module. 7. Install the airbag module and tighten bolts to 12 to 14 Nm (105 to 125 in lb) torque. 8. Connect the speed control wires to the switches and install switches. Tighten screws to 2 Nm. (20 in lb) torque. 9. Do not connect the battery negative cable. Refer to Airbag System Arming procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Diagnostic Connector, Air Bag > Component Information > Locations Diagnostic Connector: Locations Data Link Connector Same as powertrain data link connector. Airbag information is transferred over the CCD (Information) Bus -- and can be read through the data link connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Diagnostic Connector, Air Bag > Component Information > Locations > Page 5527 Data Link Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Diagnostic Connector, Air Bag > Component Information > Locations > Page 5528 Diagnostic Connector: Description and Operation Data Link Connector Same as powertrain data link connector. Airbag information is transferred over the CCD (Information) Bus -- and can be read through the data link connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Drivers Side Impact Sensor: Locations Drivers Side Driver Air Bag Module, Data Link Connector And Impact Sensor Locations Fig. 10 Impact Sensor Location Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Drivers Side > Page 5533 Impact Sensor: Locations Passengers Side Passenger Air Bag Module And Impact Sensor Locations Fig. 10 Impact Sensor Location Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 5534 Impact Sensor: Diagrams Left Impact Sensor Right Impact Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor Circuit Operation Impact Sensor: Description and Operation Impact Sensor Circuit Operation CIRCUIT OPERATION Two airbag impact sensors provide input to the Airbag Control Module (ACM). Each sensor has two circuits that connect to the ACM. From the left impact sensor, Circuit R47 connects to the ACM at cavity 2 of the 13-way connector. Circuit R49 connects to cavity 1 of the 13-way connector. From the right impact sensor, Circuit R46 connects to the ACM at cavity 12 of the 13-way connection Circuit R48 connects to cavity 13 of the 13-way connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor Circuit Operation > Page 5537 Impact Sensor: Description and Operation Impact Sensor Operation FRONT IMPACT SENSORS The Driver/Passenger Airbag System is a supplemental safety device designed to help protect the driver/passenger from serious injury, caused by a frontal impact of the vehicle. The two front impact sensors provide verification of the direction and severity of the impact. The sensors are mounted on the left and right side of the radiator closure panel under the vehicle's hood. The impact sensors are threshold sensitive switches that complete an electrical circuit when an impact provides a sufficient acceleration to close the switch. The sensors are calibrated for the specific vehicle and react to the severity and direction of the impact. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor Impact Sensor: Service and Repair Left Impact Sensor Fig. 7 Remove Or Install Battery Cable WARNING: Before beginning any airbag system component removal or installation procedures, disconnect and isolate the battery negative (ground) cable. This will disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. 1. Remove battery negative cable and battery positive cable in this order. 2. Remove battery thermoguard. 3. Remove battery hold down clamp and battery from vehicle. 4. Remove battery tray and air inlet hose. Fig. 10 Impact Sensor Location 5. Remove sensor and disconnect impact sensor electrical connector. Fig. 11 Impact Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor > Page 5540 6. For installation, reverse above procedures. Install sensor (arrow pointed forward as shown, to the stud plate on the closure panel, using three nuts provided with new sensor and tighten to 6 Nm (50 in lb) torque. Do not connect battery negative cable. Refer to Airbag System Check for proper procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor > Page 5541 Impact Sensor: Service and Repair Right Impact Sensor Fig. 7 Remove Or Install Battery Cable WARNING: Before beginning any airbag system component removal or installation procedures, disconnect and isolate the battery negative (ground) cable. This will disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. 1. Remove battery negative cable and battery positive cable in this order. 2. Remove radiator fan module. 3. Drain and remove radiator. Fig. 10 Impact Sensor Location 4. Remove three nuts holding sensor to stud plate on the closure panel. 5. Remove sensor and disconnect impact sensor electrical connector. Fig. 11 Impact Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor > Page 5542 6. For installation, reverse above procedures. Install sensor (arrow pointed forward as shown, to the stud plate on the closure panel, using three nuts provided with new sensor and tighten to 6 Nm (50 in lb) torque. Do not connect battery negative cable. Refer to Airbag System Check for proper procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations Malfunction Lamp / Indicator: Locations The warning lamp is located in the instrument cluster. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations > Page 5546 Airbag Warning Lamp Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations > Page 5547 Malfunction Lamp / Indicator: Description and Operation CIRCUIT OPERATION The Airbag Warning lamp is used to alert the operator of a problem with the Airbag system. The lamp is illuminated when the Airbag Control Module (ACM) grounds the R41 circuit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations > Page 5548 Malfunction Lamp / Indicator: Testing and Inspection - Check for blown fuses in the circuit that connect to the ignition switch and those that connect to the Airbag Control Module (ACM). - While the bus bars in the fuse block power the ACM, they also feed additional components on separate fuse protected circuits. - The ACM has a case ground and an external dedicated ground. The dedicated ground connects to the instrument panel right center support. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5553 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5554 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5555 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5556 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5557 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Air Bag Replacement - Control Module Requirements Air Bag Control Module: Technical Service Bulletins Air Bag Replacement - Control Module Requirements NO: 08-04-96 GROUP: Electrical DATE: Feb. 9, 1996 SUBJECT: Air Bag Replacement - Control Module Requirements MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL 1996 NEON VEHICLES BUILT PRIOR TO 01-02-96 (MDH O1-02-xx). DISCUSSION: When replacing a passenger side airbag on 1996 Neon vehicles built prior to January 2, 1996, the airbag control module must also be replaced using P/N 5269907. If the control module is not replaced, the airbag warning light will illuminate when the ignition is turned on following service. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5563 Air Bag Control Module Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5564 Air Bag Control Module: Diagrams Airbag Control Module Connector -- 13 Way Airbag Control Module Connector -- 4 Way Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5565 Air Bag Control Module: Description and Operation OPERATION The ACM/Air Bag System Diagnostic Module (ASDM) contains safing sensor and energy reserve capacitor, while the ACM/Air Bag Electronic Control Module (AECM) contains impact sensor and energy reserve capacitor. The ACM monitors system to determine system readiness. The ACM will store sufficient energy to deploy air bag for two minutes after battery has been disconnected. The ACM contains an on board diagnostics function that will illuminate air bag warning lamp when a system fault occurs. CIRCUIT OPERATION Two different circuits supply battery voltage from the fuse block to the Airbag Control Module (ACM), F15 and F25. The F15 and F25 circuits are connected to separate bus bars internal to the fuse block. Different circuits from the Power Distribution Center (PDC) and ignition switch supply battery voltage to the fuse block bus bars. The F25 circuit supplies battery voltage to the ACM only when the ignition switch is in the RUN position. The F15 circuit powers the ACM when the ignition switch is in either the START or RUN position. An internal bus bar in the ignition switch connects the A1 circuit from the PDC to the A21 circuit when the switch is either the START or RUN position. The A21 circuit supplies battery voltage to the bus bar in the fuse block that feeds the F15 circuit. A 30 Amp fuse in the PDC protects the A1 and A21 circuits. A 10 Amp fuse in the fuse block, cavity 9, protects the F15 circuit. When the ignition switch is in the RUN position, it connects the A2 circuit from the PDC to the A22 circuit. The A22 circuit supplies battery voltage to the fuse block bus bar that feeds the F25 circuit. A 40 Amp fuse in the PDC protects the A2 and A22 circuits. A 10 Amp fuse in the fuse block, cavity 5, protects the F25 circuit. The ACM has a case ground and an external dedicated ground, circuit Z6. The dedicated ground connects to the instrument panel right center support. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5566 Air Bag Control Module: Service and Repair WARNING: The ACM contains a safing sensor which enables the system to deploy the airbags. To avoid accidental deployment, never connect ACM electrically to the system while vehicle battery is connected. Disconnect and isolate the battery negative (ground) cable before beginning any airbag system component removal or installation procedure. This will disable the airbag system. Failure to disconnect battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for 2 minutes before removing any airbag components. CAUTION: Failure to follow the parking brake service procedures can result in damage to the parking brake mechanism. WARNING: The auto adjusting feature of this parking brake lever assembly contains a clock spring loaded to approximately 20 pounds. DO NOT release the auto adjuster lockout device before installing cables into the equalizer. Keep hands out of auto adjuster sector and pawl area. Failure to observe caution in handling this mechanism could lead to serious injury. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Manual transaxle only, remove shifter knob fastener and remove shifter knob. Fig 6 Attaching Screws At Rear Of Center Console With/Without Arm Rest Fig 7 Attaching Screws At Rear Of Center Console With Arm Rest 3. Remove screws attaching rear of center console assembly to console bracket. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5567 Fig 8 Attaching Screws At Front Of Center Console 4. Remove the two screws located in cup holders, attaching front of center console assembly to console bracket. 5. Raise park brake hand lever assembly as high as it will go for required clearance to remove center console. 6. Remove center console assembly from vehicle. WARNING: When repairs to the park brake hand lever assembly or cables is required, the auto adjuster must be reloaded and locked out. 7. Lower park brake lever handle. Fig 9 Locking Pin Installed In Park Brake Mechanism 8. Grasp park brake lever output cable by hand and pull upward. - Continue pulling on cable until a 3/16 in. drill bit can be inserted into handle and sector gear of park brake mechanism. - This will lock the park brake mechanism and take tension off park brake cables. Fig 10 Removing Park Brake Cables From Equalizer Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5568 9. Remove both rear park brake cables from the park brake cable equalizer. Fig 11 Brake Warning Lamp Connection To Park Brake Lever 10. Remove wiring harness electrical connector for brake warning light from park brake lever. Fig 12 Park Brake Lever Attachment To Console Bracket 11. Remove the two nuts attaching park brake lever to console bracket. Remove park brake lever mechanism from vehicle. Fig 13 Airbag Control Module 12. Remove module mounting nuts and remove module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5569 Fig 14 ACM Connectors 13. Disconnect ACM 4-way and 13-way connectors. 14. Remove Airbag Control Module. INSTALLATION 1. Connect both ACM connectors and ensure both connectors and all locking tabs are engaged. CAUTION: USE SUPPLIED SCREWS ONLY. 2. Position ACM (arrow pointing forward) in the console floor bracket, attach the nuts and tighten to 11 to 14 Nm (105 to 125 in lb) torque. NOTE: The park brake lever can be in any position when releasing the auto adjuster. To ease installation of center console, it is advisable to pull park brake lever handle all the way up before removing lockout pin. 3. Place park brake lever on console bracket. - Install and securely tighten the 2 attaching nuts. Fig 15 Park Brake Cables Properly Installed In Equalizer Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5570 Fig 16 Rear Park Brake Cable Installation On Equalizer 4. Install both rear park brake cables into equalizer on park brake lever output cable. 5. Ensure that park brake cable is correctly installed and aligned with cable track on park brake lever. 6. Pull park brake lever handle all the way up. Fig 17 Removing Lockout Pin From Park Brake Lever Assembly 7. Firmly grasp park brake lever locking pin and quickly remove it from the park brake lever mechanism. This will allow the park brake lever mechanism to correctly adjust the park brake cables. Fig 18 Brake Warning Lamp Connection To Park Brake Lever 8. Connect electrical connector for brake warning lamp onto terminal on park brake lever assembly. 9. Cycle park brake lever once to position park brake cables. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 5571 - Then return the park brake lever its released position. - Check the rear wheels of the vehicle -- they should rotate freely without dragging. 10. Raise park brake lever to its fully engaged position. - This is necessary to allow installation of the center console. 11. Install center console assembly Fig 19 Attaching Screws At Rear Of Center Console With/without Arm Rest Fig 20 Attaching Screws At Rear Of Center Console With Arm Rest Fig 21 Attaching Screws At Front Of Center Console 12. Install the four center console assembly attaching screws. 13. Replace shifter knob and fastener. 14. Do not connect battery negative cable. Refer to Airbag System Check for proper procedure. See: Air Bag Systems/Testing and Inspection Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 WARNINGS: - 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. - 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, use proper and safe service procedures . Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: 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 disarm the system. NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). 1. Disconnect and isolate the battery negative (ground) cable. 2. 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 air-bag deployment and possible personal injury. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 5578 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming WARNING: Before attempting to diagnose, remove or install any airbag system components, first disconnect and isolate battery ground cable, then wait at least 2 minutes prior the performing any service. - Failure to do so may result in airbag deployment or personal injury. 1. Connect the scan tool to the Data Link connector which is located on the left side kick panel just above the hood release. 2. Turn the ignition key to the ON position. Exit vehicle with the scan tool. Use the latest version of the diagnostic cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative remote terminal. 4. Using the scan tool, read and record the active diagnostic trouble code data. 5. Read and record any stored diagnostic trouble codes. 6. Refer to Powertrain Management/Computers and Controls/Body Control Module if any diagnostic trouble codes are found in Step 4 and Step 5. 7. Erase stored diagnostic trouble codes if there are no active diagnostic trouble codes. If problems remain, diagnostic trouble codes will not erase. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. If the airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Tether Installation NUMBER: 23-029-08 GROUP: Body DATE: October 24, 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. B, DATED NOVEMBER 24, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DEALERS PLEASE NOTE, THIS IS REIMBURSABLE REGARDLESS OF VEHICLE AGE OR MILEAGE. SUBJECT: Child Seat Tether Anchor Installation OVERVIEW: This bulletin describes procedures to install Child Seat Tether Anchors based on Customer Request. NOTE: Dealers are encouraged to honor any customers request for the installation of the Child Seat Tether Anchors and Dealer reimbursement will be made by Chrysler regardless of vehicle age or mileage. See the Warranty Policy and Procedure Manual and or Warranty Bulletin D-08-33 for reimbursement detail. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shawdow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5584 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year and later. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. Chrysler is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. NOTE: This bulletin is provided to identify the parts and labor operation numbers necessary to install a Child Seat Tether Anchor. Each dealer is encouraged to install these kits based on customer request and Chrysler will reimburse any Chrysler / Dodge / or Jeep dealer installing these kits regardless of vehicle age or mileage. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5585 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5586 PARTS REQUIRED: POLICY: Customer Satisfaction, Reimbursable regardless of mileage or age. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5587 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5588 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5589 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5590 Child Seat Tether Attachment: Technical Service Bulletins Child Seat Tether Anchor - Labor/Parts Identification NUMBER: 23-35-99 Rev. A GROUP: Body DATE: Oct. 1, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-35-99 DATED SEPTEMBER 3, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES IN SOME TIME ALLOWANCES. SUBJECT: Child Seat Tether Anchors NOTE: THIS BULLETIN DOES NOT APPLY TO DAIMLERCHRYSLER CANADA DEALERS. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) LeBaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2000 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light truck in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5591 detailed instruction sheet. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5592 PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5593 POLICY: Customer Satisfaction Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5594 TIME ALLOWANCE: Failure Code: CG - Customer Satisfaction Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5595 Child Seat Tether Attachment: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5596 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5597 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5598 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5599 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5600 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Interior - Seat Belt Cinch Bar Service Seat Belt: Technical Service Bulletins Interior - Seat Belt Cinch Bar Service NUMBER: 08-010-03 GROUP: Electrical DATE: Apr.25, 2003 SUBJECT: Seat Belt Cinch Bar Service MODELS: 2001 - 2003 (AB) Ram Van/Wagon (Front Passenger Seat Belt Only) 1994 (BR) Ram Pickup 1996-2002 (BR/BE) Ram Pickup 2001 - 2003 (DN) Durango (Front Passenger Seat Belt Only) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 1996 - 2000 (JX) Sebring Convertible 1995 - 2003 (PL) Neon/SX 2.0 2001 - 2003 (PT) PT Cruiser DISCUSSION: Any time the seat belt cinch bar (Fig. 1) is loose, missing or damaged it is no longer necessary to replace the seat belt assembly. Cinch bar repair kits are now available for the vehicles listed. If any component of the seat belt assembly has been damaged due to collision, the entire assembly must be replaced. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Interior - Seat Belt Cinch Bar Service > Page 5605 NOTE: THE CINCH BAR, CINCH BAR COVER OR ANY OTHER COMPONENT OF THE SEAT BELT ASSEMBLY MUST NEVER BE PAINTED. NOTE: INSTALLATION INSTRUCTIONS ARE INCLUDED WITH EACH KIT. PARTS REQUIRED: NOTE: SELECT THE COLOR CLOSEST TO THE SEAT BELT ASSEMBLY COLOR. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 5606 Seat Belt: Service and Repair FRONT OUTBOARD SEAT BELT Removal 1. Slide lower seat belt anchor cover upward to expose bolt. Front Outboard Seat Belt Anchor 2. Remove bolt holding lower anchor bolt to floor below door sill. 3. Separate lower anchor from floor. 4. Remove rear seat cushion and back. 5. Remove quarter trim panel. 6. Guide seat belt webbing through slot in quarter trim panel. 7. Disengage wire connector from seat belt retractor. Front Outboard Seat Belt Retractor 8. Remove bolts holding seat belt retractor to B-pillar. 9. Separate seat belt retractor from vehicle. Installation Reverse the preceding operation. Tighten seat belt anchor bolt to 39 Nm (29 ft. lbs.). FRONT SEAT BELT BUCKLE 1. Move front seat to the forward position. 2. Remove bolt holding seat belt buckle to seat. 3. Separate seat belt buckle from scat. 4. Reverse the preceding operation for installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 5607 FRONT SEAT BELT RETRACTOR 1. Remove B-pillar trim. 2. Remove bolt holding seat belt retractor to B-pillar. 3. Separate seat belt retractor from vehicle. 4. Reverse the preceding operation for installation. REAR SEAT BELT BUCKLE 1. Remove rear seat cushion. 2. Remove rear seat back. 3. Separate rear seat belt buckle from vehicle. 4. Reverse the preceding operation for installation. REAR SEAT BELT RETRACTOR 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 holding seat belt lower anchor to floor. Rear Seat Belt Retractor 5. Remove bolt holding retractor to rear seat closure panel. 6. Push seat belt bezel and buckle stab through access hole in parcel shelf. 7. From in luggage compartment, separate rear seat belt retractor from vehicle. 8. Reverse the preceding operation for installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair Seat Belt Height Adjuster: Service and Repair Front Shoulder Belt Adjuster FRONT SHOULDER BELT ADJUSTER 1. Remove B-pillar trim. 2. Remove bolt holding shoulder belt adjuster to B-pillar. 3. Separate shoulder belt adjuster from vehicle. 4. Reverse the preceding operation for installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation CIRCUIT OPERATION The fasten seat belt indicator is used with the warning chime to indicate to the operator to fasten the seat belt. There is a switch located in the drivers side B-pillar that is normally OPEN with the seat belt buckled. If the seat belt is not buckled the switch CLOSES and a ground path is completed from the G10 circuit to the Z1 circuit. This will illuminate the lamp in the instrument cluster. When the ignition switch is moved to the START position the lamp will illuminate. Logic internal to the instrument cluster determines the length of time. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5619 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5620 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5621 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5622 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5623 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5624 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5625 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5626 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5627 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5628 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5629 PARTS REQUIRED: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5630 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 5631 POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Drivers Side Impact Sensor: Locations Drivers Side Driver Air Bag Module, Data Link Connector And Impact Sensor Locations Fig. 10 Impact Sensor Location Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Drivers Side > Page 5636 Impact Sensor: Locations Passengers Side Passenger Air Bag Module And Impact Sensor Locations Fig. 10 Impact Sensor Location Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 5637 Impact Sensor: Diagrams Left Impact Sensor Right Impact Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor Circuit Operation Impact Sensor: Description and Operation Impact Sensor Circuit Operation CIRCUIT OPERATION Two airbag impact sensors provide input to the Airbag Control Module (ACM). Each sensor has two circuits that connect to the ACM. From the left impact sensor, Circuit R47 connects to the ACM at cavity 2 of the 13-way connector. Circuit R49 connects to cavity 1 of the 13-way connector. From the right impact sensor, Circuit R46 connects to the ACM at cavity 12 of the 13-way connection Circuit R48 connects to cavity 13 of the 13-way connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor Circuit Operation > Page 5640 Impact Sensor: Description and Operation Impact Sensor Operation FRONT IMPACT SENSORS The Driver/Passenger Airbag System is a supplemental safety device designed to help protect the driver/passenger from serious injury, caused by a frontal impact of the vehicle. The two front impact sensors provide verification of the direction and severity of the impact. The sensors are mounted on the left and right side of the radiator closure panel under the vehicle's hood. The impact sensors are threshold sensitive switches that complete an electrical circuit when an impact provides a sufficient acceleration to close the switch. The sensors are calibrated for the specific vehicle and react to the severity and direction of the impact. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor Impact Sensor: Service and Repair Left Impact Sensor Fig. 7 Remove Or Install Battery Cable WARNING: Before beginning any airbag system component removal or installation procedures, disconnect and isolate the battery negative (ground) cable. This will disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. 1. Remove battery negative cable and battery positive cable in this order. 2. Remove battery thermoguard. 3. Remove battery hold down clamp and battery from vehicle. 4. Remove battery tray and air inlet hose. Fig. 10 Impact Sensor Location 5. Remove sensor and disconnect impact sensor electrical connector. Fig. 11 Impact Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor > Page 5643 6. For installation, reverse above procedures. Install sensor (arrow pointed forward as shown, to the stud plate on the closure panel, using three nuts provided with new sensor and tighten to 6 Nm (50 in lb) torque. Do not connect battery negative cable. Refer to Airbag System Check for proper procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor > Page 5644 Impact Sensor: Service and Repair Right Impact Sensor Fig. 7 Remove Or Install Battery Cable WARNING: Before beginning any airbag system component removal or installation procedures, disconnect and isolate the battery negative (ground) cable. This will disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. 1. Remove battery negative cable and battery positive cable in this order. 2. Remove radiator fan module. 3. Drain and remove radiator. Fig. 10 Impact Sensor Location 4. Remove three nuts holding sensor to stud plate on the closure panel. 5. Remove sensor and disconnect impact sensor electrical connector. Fig. 11 Impact Sensor Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Left Impact Sensor > Page 5645 6. For installation, reverse above procedures. Install sensor (arrow pointed forward as shown, to the stud plate on the closure panel, using three nuts provided with new sensor and tighten to 6 Nm (50 in lb) torque. Do not connect battery negative cable. Refer to Airbag System Check for proper procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Description and Operation > Illuminated Entry Keyless Entry: Description and Operation Illuminated Entry CIRCUIT OPERATION When the RKE module determines a need for the interior lamps to be turned ON, the module energizes the relay connecting circuits M23 and Z2. The M23 circuit is the ground side for many of the vehicles interior lamps. The Z2 circuit connects to the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Description and Operation > Illuminated Entry > Page 5652 Keyless Entry: Description and Operation Panic Function CIRCUIT OPERATION When the operator activates the panic function of the system the RKE module grounds the appropriate relays connecting circuits F35 and L4 to feed the headlamps, and F35 to L7 to feed the parking lamps. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Description and Operation > Illuminated Entry > Page 5653 Keyless Entry: Description and Operation Power Door Locks CIRCUIT OPERATION Power for the Remote Keyless Entry (RKE) module is supplied from three sources. Power is supplied to the RKE module on circuit G5. This circuit is protected by a 5 Amp fuse located in cavity 11 of the fuse block. Power for the fuse is supplied from the ignition switch on circuit A21. This circuit is HOT in the START and RUN position. Power for the A21 circuit is supplied by circuit A1. This circuit is HOT at all times and is protected by a 30 Amp fuse located in the Power Distribution Center (PDC). Circuit F35 supplies battery voltage to the RKE module. This circuit is HOT at all times and is protected by a 20 Amp fuse located in cavity 3 of the fuse block. Power for the fuse is supplied on circuit A3. The A3 circuit is protected by a 40 Amp fuse located in the PDC. The F35 circuit is used to supply power for the contact side of several relays internal to the RKE module. Power is also supplied by circuit M1. This is the Ignition-Off Draw (IOD) circuit and is protected by a 10 Amp fuse located in cavity 13 of the Power Distribution Center (PDC). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Description and Operation > Illuminated Entry > Page 5654 Keyless Entry: Description and Operation Time Out Relay CIRCUIT OPERATION The time out relay is located in the fuse block and is used to control the ground path for various interior lamps. It will also turn the lamps OFF after a specified period of time, and works with the Remote Keyless Entry (RKE) system for illuminated entry. Circuit M2 connects to the relay and supplied a ground path through the door ajar switches. Circuit M1 is used to supply battery voltage to the relay. This circuit is produced by a 10 Amp fuse located in cavity 13 of the Power Distribution Center (PDC). Circuit M32 is connected from the relay to the various interior lamps and RKE module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Description and Operation > Illuminated Entry > Page 5655 Keyless Entry: Description and Operation Illuminated Entry CIRCUIT OPERATION When the RKE module determines a need for the interior lamps to be turned ON, the module energizes the relay connecting circuits M23 and Z2. The M23 circuit is the ground side for many of the vehicles interior lamps. The Z2 circuit connects to the instrument panel left center support. Panic Function CIRCUIT OPERATION When the operator activates the panic function of the system the RKE module grounds the appropriate relays connecting circuits F35 and L4 to feed the headlamps, and F35 to L7 to feed the parking lamps. Power Door Locks CIRCUIT OPERATION Power for the Remote Keyless Entry (RKE) module is supplied from three sources. Power is supplied to the RKE module on circuit G5. This circuit is protected by a 5 Amp fuse located in cavity 11 of the fuse block. Power for the fuse is supplied from the ignition switch on circuit A21. This circuit is HOT in the START and RUN position. Power for the A21 circuit is supplied by circuit A1. This circuit is HOT at all times and is protected by a 30 Amp fuse located in the Power Distribution Center (PDC). Circuit F35 supplies battery voltage to the RKE module. This circuit is HOT at all times and is protected by a 20 Amp fuse located in cavity 3 of the fuse block. Power for the fuse is supplied on circuit A3. The A3 circuit is protected by a 40 Amp fuse located in the PDC. The F35 circuit is used to supply power for the contact side of several relays internal to the RKE module. Power is also supplied by circuit M1. This is the Ignition-Off Draw (IOD) circuit and is protected by a 10 Amp fuse located in cavity 13 of the Power Distribution Center (PDC). Time Out Relay CIRCUIT OPERATION The time out relay is located in the fuse block and is used to control the ground path for various interior lamps. It will also turn the lamps OFF after a specified period of time, and works with the Remote Keyless Entry (RKE) system for illuminated entry. Circuit M2 connects to the relay and supplied a ground path through the door ajar switches. Circuit M1 is used to supply battery voltage to the relay. This circuit is produced by a 10 Amp fuse located in cavity 13 of the Power Distribution Center (PDC). Circuit M32 is connected from the relay to the various interior lamps and RKE module. Using Door Lock Switches CIRCUIT OPERATION Operation of the lock and unlock functions is the same as systems without Remote Keyless Entry (RKE). The only change between the systems is all of the lock and unlock circuits pass through the RKE module. Left Door Unlock CIRCUIT OPERATION When the operator selects left front UNLOCK the Remote Keyless Entry (RKE) module energizes the left front unlock relay connecting circuits F35 and P34. Circuit P34 connects from the module to the door lock motor. Ground for the motor is supplied on circuit P33 through a bus bar in the right switch to circuit P35. The P35 circuit connects from the switch to the LOCK-ALL relay in the RKE module. Ground is passed through the normally CLOSED contacts in the relay to the left door switch. Ground is passed through a bus bar in the switch to circuit Z8. This circuit terminates at the instrument panel left center support. Lock-All CIRCUIT OPERATION When the operator selects LOCK ALL the Remote Keyless Entry (RKE)module energizes the lock all relay connecting circuits F35 and P35. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Description and Operation > Illuminated Entry > Page 5656 Circuit P35 connects from the module to the passengers and drivers door switch, lock side. Power is passed through the bus bar in the passengers switch to circuit P33. This circuit connects to the LOCK side of the motors. Ground for the motors is supplied on circuit P34 through a bus bar in the right switch to circuit P36. The P36 circuit connects from the switch to the UNLOCK-ALL relay in the RKE module. Ground is passed through the normally CLOSED contacts in the relay to the left door switch. Ground is passed through a bus bar in the switch to circuit Z8. This circuit terminates at the instrument panel left center support. Unlock-All CIRCUIT OPERATION When the operator selects UNLOCK ALL the Remote Keyless Entry (RKE)module energizes the unlock all relay connecting circuits F35 and P36. Circuit P36 connects from the module to the passengers and drivers door switch, unlock side. Power is passed through the bus bar in the passengers switch to circuit P34. This circuit connects to the UNLOCK side of the motors. Ground for the motors is supplied on circuit P33 through a bus bar in the right switch to circuit P35. The P35 circuit connects from the switch to the LOCK-ALL relay in the RKE module. Ground is passed through the normally CLOSED contacts in the relay to the left door switch. Ground is passed through a bus bar in the switch to circuit Z8. This circuit terminates at the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Component Information > Description and Operation > Page 5657 Keyless Entry: Testing and Inspection - Check the 40 Amp fuse in the PDC. - Check the 15 Amp fuse in cavity 3 of the fuse block. - Check the grounding point on the instrument panel left center support brace. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5662 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5663 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5664 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5669 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5670 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 5671 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair Driver/Vehicle Information Display: Service and Repair 1. Disconnect battery ground cable. 2. Remove instrument panel top cover and cluster bezel. 3. Remove four screws attaching cluster housing to base panel. 4. Pull cluster rearward to disconnect from base panel. 5. Remove cluster assembly. 6. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > CD Player - CD Compatibility Compact Disc Player (CD): Technical Service Bulletins CD Player - CD Compatibility BULLETIN NUMBER: 08-11-00 GROUP: Electrical DATE: March 24, 2000 SUBJECT: Recordable Compact Discs Used in Automotive CD players MODELS: 1989 - 2000 (AB) Ram Van/Wagon 1989 - 2000 (AN) Dakota 1994 - 2000 (BR/BE) Ram Truck 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GT 1997 - 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee DISCUSSION: Some recordable compact disc media, such as CD-R and CD-RW, may not comply with the standard CD format used in automotive CD players. When these CD's are used, customers may encounter error messages, skipping, or delaminating of the labels, which can cause an eject failure. It is important to question whether these kinds of CD media are being used. When customers encounter these symptoms, check the system with a known playable CD. Explain that the media may not be compatible with some automotive CD players. Replacing or exchanging the CD player will not address these issues. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5684 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5685 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5686 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5687 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5688 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5689 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5690 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5691 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5692 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5693 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5694 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5695 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5696 Radio/Stereo: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5697 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5698 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5699 Radio/Stereo: Electrical Diagrams Audio Systems (Part 1 Of 3) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5700 Audio Systems (Part 2 Of 3) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 5701 Audio Systems (Part 3 Of 3) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Description and Operation > Radio Operation Radio/Stereo: Description and Operation Radio Operation CIRCUIT OPERATION When the ignition switch is in either the ACCESSORY or RUN position, it connects circuit A1 from the Power Distribution Center (PDC) to circuit A31. Circuit A31 powers a bus bar in the fuse block. The bus bar feeds two circuits, one of which is circuit X12. Circuit X12 powers the radio. A 10 Amp fuse, in cavity 16 of the fuse block, protects circuit X12. Circuit Z9 supplies the ground path for the radio. The grounding point for circuit Z9 is the instrument panel right center support. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Description and Operation > Radio Operation > Page 5704 Radio/Stereo: Description and Operation Radio Memory CIRCUIT OPERATION Circuit M1 from the Power Distribution Center (PDC) supplies power for the radio memory. The circuit contains the Ignition Off Draw (IOD) fuse. The IOD fuse is removed during vehicle shipping to prevent excessive battery draw. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Description and Operation > Radio Operation > Page 5705 Radio/Stereo: Description and Operation Radio Illumination CIRCUIT OPERATION When the parking lamps or headlamps are ON, circuits E2 and L7 power the radio illumination lamps and park lamps. Circuit E2 feeds the illumination lamp. Circuit L7 feeds the park lamps of the radio. Circuit F33 feeds circuit L7. A 4 Amp fuse, in cavity 12 of the fuse block, protects circuit E2. A 15 Amp fuse, in cavity 2 of the fuse block, protects circuits L7 and F33. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Description and Operation > Page 5706 Radio/Stereo: Service and Repair 1. Disconnect battery ground cable. 2. Remove center module bezel. 3. Remove two mounting screws on radio to remove from instrument panel. 4. Disconnect wiring and antenna lead from radio. 5. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation Speaker: Description and Operation CIRCUIT OPERATION Circuit X53 feeds the speaker in the left front door. Circuit X55 is the return from the speaker to the radio. On the premium system the X53 and X55 circuits are connected in with the instrument panel speaker. Circuit X54 feeds the speaker in the right front door. Circuit X56 is the return from the speaker to the radio. On the premium system the X54 and X56 circuits are connected in with the instrument panel speaker. Circuit X51 feeds the left rear speaker Circuit X57 is the return from the speaker to the radio. Circuit X52 feeds the right rear speaker. Circuit X58 is the return from the speaker to the radio. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Page 5710 Speaker: Testing and Inspection - Circuit M1 also powers the vanity lamps, glove box lamp, time delay relay, dome lamps, underhood lamp, cargo lamp, and power mirrors. - If the radio does not operate, check for blown fuses in circuits A1 and X12. - Circuits A3, and F33 feed the L7 circuit. - If the radio illumination lamps do not operate, check for blown fuses in circuits E2, F33, and A3. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > System Information > Service and Repair Front Door Handle: Service and Repair REMOVAL 1. Remove door trim panel and water shield. 2. Close door glass. 3. Disconnect lock and latch rods from door latch. Front Door Outside Handle 4. Remove nut holding door handle retainer to outer door panel. 5. Separate retainer from back of door handle. 6. Separate door handle from vehicle. INSTALLATION 1. Position door handle into door and install retainer at back of handle. 2. Install nut holding door handle retainer to outer door panel. 3. Connect lock and latch rods to door latch. 4. Install door trim panel and water shield. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments Front Door Latch: Adjustments Door Latch Adjustment FRONT DOOR LATCH ADJUSTMENT 1. Insert a hex-wrench through the elongated hole in the door end frame near the latch striker opening. 2. Loosen socket head screw on the side of the latch linkage. 3. Lift upward on outside door handle and release it. 4. Tighten socket head screw on latch. 5. Verify latch operation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments > Page 5721 Front Door Latch: Service and Repair REMOVAL 1. Remove door trim panel and water shield. 2. Close door glass. Front Door Latch 3. Disconnect lock and latch rods from door latch. 4. Disengage wire connector from power door lock motor, if equipped. 5. Remove screws holding latch to door end frame. 6. Separate door latch from vehicle. INSTALLATION CAUTION: Do not close door before adjusting the door latch. Door may fail to re-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 Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior - Door Trim Panel Service Revisions Front Door Panel: Technical Service Bulletins Interior - Door Trim Panel Service Revisions NUMBER: 26-07-96A GROUP: Miscellaneous DATE: July, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1996 Neon - Publication Number 81-370-6025 DESCRIPTION OF CHANGES Revisions to the door trim panel procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior - Door Trim Panel Service Revisions > Page 5726 23-20 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior - Door Trim Panel Service Revisions > Page 5727 23-21 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim-2 Door Models Front Door Panel: Service and Repair Front Door Trim-2 Door Models The content of this article reflects changes called for in TSB 26-07-96. REMOVAL 1. Release door latch and open door. 2. Lower door glass. Front Door Pull Cup 3. Remove screw inside pull cup holding door trim panel to bracket. 4. Pull and hold inside door handle away from door trim. Inside Door Handle Screw 5. Remove screw holding trim panel to door from behind inside door handle. Window Crank Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim-2 Door Models > Page 5730 6. Remove window regulator crank, if so equipped. Door Trim Panel 7. Disengage hidden clips holding trim panel to door from around perimeter of trim panel. 8. Tilt trim panel outward to clear locator pins on backside of trim panel. 9. Disengage trim panel from retainer channel at the top of the door. Inside Door Handle Linkage 10. Move trim panel away from door and disengage clip holding door latch linkage to back of inside door handle. 11. Separate latch rod from handle. Caution: Do not allow door trim panel to hang by the wire connector or wiring. 12. Disengage wire connector from power door lock switch, mirror switch, and power window switch, if so equipped. 13. Separate trim panel from vehicle. INSTALLATION 1. Replace any damaged or missing push-in fasteners from around perimeter of door trim panel. 2. Place trim panel near door. 3. Engage wire connector to power lock switch, mirror switch, and power window switch, if so equipped. 4. Attach latch rod to inside door handle. 5. Engage clip holding door latch linkage to back of inside door handle. 6. Engage trim panel into retainer channel at top of door. 7. Locate door trim panel to inner door panel by aligning locating pins on backside of trim panel to mating holes in inner door panel. 8. Engage hidden clips holding trim panel to door from around perimeter of trim panel. 9. With the window in the down position, orientate the window regulator crank handle appropriately Install the right handle at the 10 o'clock position and the left handle at the 2 o'clock position, if so equipped. 10. Install screw holding trim panel to door from behind inside door handle. 11. Install screw inside pull cup holding door trim panel to bracket. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim-2 Door Models > Page 5731 Front Door Panel: Service and Repair Front Door Trim-4 Door Models The content of this article reflects changes called for in TSB 26-07-96. REMOVAL 1. Release door latch and open door. Window Crank 2. Remove window regulator crank, if so equipped. Front Door Trim 3. Remove screw from inside arm rest pull cup. 4. Remove screw form behind inside latch release handle. 5. Disengage push-in fasteners holding trim to door panel around perimeter of trim panel. 6. Tilt trim panel outward to clear locator pins on backside of trim panel. 7. Disengage trim panel from retainer channel at top of door. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim-2 Door Models > Page 5732 Inside Door Handle Linkage 8. Move trim panel away from door and disengage clip holding latch rod to handle. 9. Separate latch rod from handle. Caution: Do not allow door trim panel to hang by the wire connector or wiring. 10. Disengage wire connector from power door lock switch, mirror switch, and power window switch if so equipped. 11. Separate 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. Engage 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. Engage trim panel into retainer channel at top of door. 6. Locate door trim panel to inner door panel by aligning locating pins on backside of trim panel to mating holes in inner door panel. 7. Engage push-in fasteners to bold trim to door panel around perimeter of trim panel. 8. Install screw behind inside latch release handle. 9. Install screw inside arm rest pull cup. 10. With the window in the down position, orientate the window regulator crank handle appropriately. Install the right handle at the 10 o'clock position and the left handle at the 2 o'clock position, if so equipped. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim-2 Door Models > Page 5733 Front Door Panel: Service and Repair Front Door Water Shield REMOVAL 1. Remove door trim panel. 2. Remove Door speaker, if equipped. 3. Remove door trim pull cup mount bracket. 4. Disengage clip holding lock linkage to lock button bell crank. Water Shield 5. Peel water shield away from adhesive around perimeter of inner door panel. INSTALLATION 1. Insure that enough adhesive remains to securely retain the watershield. Replace as necessary. 2. Place the watershield into position and press securely to adhesive making sure to properly route wiring and linkages. 3. Engage clip holding lock linkage to lock button bell-crank. 4. Install door trim pull cup mount bracket. 5. Install door speaker, if equipped. 6. Install door trim panel. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 FRONT DOOR INNER BELT WEATHERSTRIP Removal 1. Remove door trim panel. Front Door Inner Belt Weatherstrip 2. Separate weatherstrip from door. Installation 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. WINDOW INNER BELT STABILIZER Removal 1. Remove door trim panel. 2. Remove nut holding inner belt stabilizer to door panel. Inner Belt Stabilizer 3. Separate inner belt stabilizer from door. Installation Reverse the preceding operation. Adjust inner belt stabilizer against glass with enough tension to allow free up and down movement. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Page 5737 Outer Belt Weatherstrip FRONT DOOR OUTER BELT WEATHERSTRIP Removal 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. 3. Separate outer belt weatherstrip from vehicle. Installation 1. Starting at leading edge of door, press weatherstrip onto door. 2. Operate window and check for interference Rear Door Inner Belt Weatherstrip REAR DOOR INNER BELT WEATHERSTRIP Removal 1. Remove door trim panel. 2. Pull weatherstrip from top of door panel. 3. Separate weatherstrip from door. Installation 1. Place inner belt weatherstrip in position on door. 2. Push down on weatherstrip to engage channel to door panel. 3. Install door trim panel. REAR DOOR OUTER BELT WEATHERSTRIP Removal 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Page 5738 Outer Belt Weatherstrip 3. Separate outer belt weatherstrip from vehicle. 4. Reverse the preceding operation for installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair REMOVAL 1. Remove door trim panel and water shield. 2. Remove inner and outer door belt weatherstrips. 3. Loosen inner belt stabilizer. 4. Lower door glass to bottom of travel to access glass attachment bolts. Regulator Lift Channel 5. Remove bolts holding regulator lift channel to door glass. Guide Bolts 6. Remove bolts holding rear guide plate to door glass. 7. Separate rear guide plate from door glass. Door Glass Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair > Page 5742 8. Lift door glass upward and out of opening at top of door. 9. Remove front guide plate from door glass. INSTALLATION 1. Install front guide plate to door glass. 2. Carefully lower door glass through opening in top of door. 3. Position rear guide plate onto door glass and install bolts. 4. Install nuts holding regulator lift channel to door glass. 5. Tighten all door glass fasteners. 6. Tighten window inner belt stabilizer. 7. Install inner and outer door belt weatherstrips. 8. Install door trim panel and water shield. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Adjustments Rear Door Latch: Adjustments Door Latch Adjustment 1. Insert a hex-wrench through the elongated hole in the door end frame near the latch striker opening. 2. Loosen socket head screw on the side of the latch linkage. 3. Lift upward on outside door handle and release it. 4. Tighten socket head screw on latch. 5. Verify latch operation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Adjustments > Page 5747 Rear Door Latch: Service and Repair REMOVAL 1. Remove door trim panel and water shield. 2. Close door glass. 3. Disconnect lock and latch rods from door latch. 4. Disengage wire connector from power door lock motor, if equipped. Rear Door Latch 5. Remove screws holding latch to door end frame. 6. Separate door latch from vehicle. INSTALLATION CAUTION: Do not close door before adjusting the door latch. Door may fail to open. 1. Position door latch on vehicle and install screws holding latch to door end frame. 2. Engage wire connector to power door lock motor, if so equipped. 3. Connect lock and latch rods to door latch. 4. Install watershield and door trim panel. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair Rear Door Panel: Service and Repair Front Door Trim REMOVAL 1. Release door latch and open door. 2. Remove window regulator crank, if equipped. 3. Remove screw from inside arm rest pull cup. 4. Remove screw form behind inside latch release handle. 5. Disengage push-in fasteners holding trim to door panel around perimeter of trim panel. 6. Disengage trim panel from retainer channel at top of door. 7. Tilt top of trim panel away from door and disengage clip holding latch rod to handle. 8. Separate latch rod from handle. 9. Separate 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 to hold 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, if equipped. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair Rear Door Weatherstrip: Service and Repair FRONT DOOR INNER BELT WEATHERSTRIP Removal 1. Remove door trim panel. Front Door Inner Belt Weatherstrip 2. Separate weatherstrip from door. Installation 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. WINDOW INNER BELT STABILIZER Removal 1. Remove door trim panel. 2. Remove nut holding inner belt stabilizer to door panel. Inner Belt Stabilizer 3. Separate inner belt stabilizer from door. Installation Reverse the preceding operation. Adjust inner belt stabilizer against glass with enough tension to allow free up and down movement. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Page 5754 Outer Belt Weatherstrip FRONT DOOR OUTER BELT WEATHERSTRIP Removal 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. 3. Separate outer belt weatherstrip from vehicle. Installation 1. Starting at leading edge of door, press weatherstrip onto door. 2. Operate window and check for interference Rear Door Inner Belt Weatherstrip REAR DOOR INNER BELT WEATHERSTRIP Removal 1. Remove door trim panel. 2. Pull weatherstrip from top of door panel. 3. Separate weatherstrip from door. Installation 1. Place inner belt weatherstrip in position on door. 2. Push down on weatherstrip to engage channel to door panel. 3. Install door trim panel. REAR DOOR OUTER BELT WEATHERSTRIP Removal 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Page 5755 Outer Belt Weatherstrip 3. Separate outer belt weatherstrip from vehicle. 4. Reverse the preceding operation for installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair REMOVAL 1. Remove door trim panel and water shield. 2. Remove inner door belt weatherstrip. 3. Loosen door glass jounce bumper. 4. Lower door glass to bottom of door. Rear Door Glass 5. Remove nuts holding door glass to window regulator lift plate. 6. Disengage door glass from regulator. 7. Lift door glass upward out of the opening at the top of door. INSTALLATION 1. Lower door glass through opening in top of door and into position in the window regulator. 2. Install nuts holding door glass to window regulator lift plate. 3. Raise glass and tighten window inner belt stabilizer. 4. Install inner door belt weatherstrip, watershield and door trim panel. 5. Operate window and check for interference. Adjust glass as necessary Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Component Information > Technical Service Bulletins > Customer Interest for Hood: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad Hood: Customer Interest Fresh Air Duct - Contacts Hood Insulator Pad NO: 14-05-96 GROUP: Fuel DATE: June 7, 1996 SUBJECT: Wear Marks On Fresh Air Duct And Hood Pad MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES BUILT WITH SPORT/EXPRESSO BUBBLE HOODS AND 2.0L SOHC ENGINES. SYMPTOM/CONDITION: Wear marks on either the fresh air duct or hood pad, due to contact between the two components may be visible. The contact between the fresh air duct and hood pad do not result in a functional problem, but the indentations may be objectional to the customer. PARTS REQUIRED: 1 4669962 Duct, Fresh Air REPAIR PROCEDURE: This bulletin involves the installation of a new fresh air duct which provides additional clearance. 1. Remove the plastic wing nut from the fresh air duct mount. See Illustration. 2. Remove the fresh air duct from the air cleaner box. 3. Install new fresh air duct (P/N 4669962) in the air cleaner box. CAUTION: THE FRESH AIR DUCT MUST BE COMPLETELY SNAPPED INTO THE AIR CLEANER BOX. VERIFY THAT THE DUCT IS FIRMLY IN PLACE. 4. Install the wing nut, while pushing down in the marked area of the fresh air duct. See Illustration. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Component Information > Technical Service Bulletins > Customer Interest for Hood: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad > Page 5767 TIME ALLOWANCE: Labor Operation No: 14-10-29-92 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad Hood: All Technical Service Bulletins Fresh Air Duct - Contacts Hood Insulator Pad NO: 14-05-96 GROUP: Fuel DATE: June 7, 1996 SUBJECT: Wear Marks On Fresh Air Duct And Hood Pad MODELS: 1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO ALL VEHICLES BUILT WITH SPORT/EXPRESSO BUBBLE HOODS AND 2.0L SOHC ENGINES. SYMPTOM/CONDITION: Wear marks on either the fresh air duct or hood pad, due to contact between the two components may be visible. The contact between the fresh air duct and hood pad do not result in a functional problem, but the indentations may be objectional to the customer. PARTS REQUIRED: 1 4669962 Duct, Fresh Air REPAIR PROCEDURE: This bulletin involves the installation of a new fresh air duct which provides additional clearance. 1. Remove the plastic wing nut from the fresh air duct mount. See Illustration. 2. Remove the fresh air duct from the air cleaner box. 3. Install new fresh air duct (P/N 4669962) in the air cleaner box. CAUTION: THE FRESH AIR DUCT MUST BE COMPLETELY SNAPPED INTO THE AIR CLEANER BOX. VERIFY THAT THE DUCT IS FIRMLY IN PLACE. 4. Install the wing nut, while pushing down in the marked area of the fresh air duct. See Illustration. POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood: > 140596 > Jun > 96 > Fresh Air Duct - Contacts Hood Insulator Pad > Page 5773 TIME ALLOWANCE: Labor Operation No: 14-10-29-92 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 Trunk Latch REMOVAL 1. Release trunk lid latch and open trunk lid. 2. Remove bolts holding trunk latch to trunk lid. 3. Separate trunk latch from trunk lid. 4. Disconnect remote trunk latch release cable from trunk latch. 5. Disengage trunk ajar switch connector from latch. 6. Separate latch from vehicle. INSTALLATION 1. Position latch in vehicle and engage trunk ajar switch connector to latch. 2. Connect remote trunk latch release cable to trunk latch. 3. Install bolts holding trunk latch to trunk lid. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 Trunk Lock Cylinder 1. Remove trunk latch. 2. Remove clip holding trunk lock cylinder to trunk lid. 3. Pull lock cylinder from trunk lid. 4. Reverse the preceding operation for installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Release Lever > Component Information > Technical Service Bulletins > Emergency Trunk Release - Availability Trunk / Liftgate Release Lever: Technical Service Bulletins Emergency Trunk Release - Availability NUMBER: 23-02-00 GROUP: Body DATE: Feb. 4, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-20-99 REV. A DATED AUGUST 13, 1999 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS INFORMATION. SUBJECT: Internal Emergency Trunk Release MODELS: 1995 - 2000 (JA) Breeze/Cirrus/Stratus 1996 - 2000 (JX) Sebring Convertible **1993 2000 (LH) Concorde/Intrepid/LHS/New Yorker/Vision/300M** 1995 - 2000 (PL) Neon NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO INSTALL AN INTERNAL EMERGENCY TRUNK RELEASE. RELEASE INSTALLATION EXPENSE IS SHARED BY DAIMLERCHRYSLER AND THE CUSTOMER. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE LABOR ONLY. THE CUSTOMER IS RESPONSIBLE FOR THE PART EXPENSE. REFER TO WARRANTY BULLETIN D-99-20 FOR CLAIMING THE LABOR EXPENSE. DISCUSSION: DaimlerChrysler Corporation is now offering internal emergency trunk releases for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the parts are available. The trunk releases are packaged in a kit containing all necessary parts and a detailed instruction sheet. PARTS REQUIRED: 1 05016812AA Kit, Emergency Trunk Release, 1995 - 2000 JA **1 05016813AA Kit, Emergency Trunk Release, 1993 - 1997 LH** 1 05016810AA Kit, Emergency Trunk Release, 1998 - 2000 LH 1 05016809AA Kit, Emergency Trunk Release, 2000 PL W/Remote Entry 1 05016811AA Kit, Emergency Trunk Release, 1994 - 1999 PL, 2000 PL W/Manual Entry 1 05016814AA Kit, Emergency Trunk Release, 1996 - 2000 JX POLICY: Customer Satisfaction Announcement TIME ALLOWANCE: Labor Operation No. 23-41-25-95 ......................................................................................................................................... .............................. 1.2 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well - Creak/Rattle on Bumps Technical Service Bulletin # 23-47-97 Date: 970926 Front Foot Well - Creak/Rattle on Bumps NO: 23-47-97 GROUP: Body EFFECTIVE DATE: Sept. 26, 1997 SUBJECT: Creak/Rattle From Front Foot Well MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Creak/rattle from driver or passenger front foot well. The creak/rattle is more pronounced over bumps. DIAGNOSIS: Drive the vehicle over a bumpy road and listen for a creak/rattle in the foot well area. If creak/rattle is heard proceed with the repair procedure on the side that the noise is heard. If the side the creak/rattle is coming from cannot be determined by sound, torque each crossmember bolt to 163 Nm (120 ft lbs). If the bolt was at 163 Nm (120 ft.lbs), the torque is acceptable and no further action is needed on that side. If the torque was not at 163 Nm (120 ft. lbs), proceed to the Repair Procedure. PARTS REQUIRED: AR(1) 05011650AA Crossmember Bolt/Nut Repair Kit (Right) AR(1) 05011651AA Crossmember Bolt/Nut Repair Kit (Left) Each kit will include one of the following components: Cage Nut, Crossmember Bolt, Crossmember Mastic Patch Drain Plug Access Hole Template POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-30-01-90 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves drilling an access hole to replace the crossmember bolt and cage nut, then sealing the access hole. 1. Raise vehicle to gain access to the crossmember bolt. 2. Remove the crossmember bolt. 3. Lower the vehicle and open the door. 4. Slide the seat to the full rearward position. Remove the floor mat if so equipped. 5. Remove the scuff plate and kick panel. 6. Pull the carpet and pad away to access the floor. 7. Prop the clutch and brake pedal to make room for drilling (drivers side only). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well - Creak/Rattle on Bumps > Page 5794 8. Insert the template, mark and center punch the floor pan (Figure 1). 9. Using a drill and 70 mm (2-3/4") Dia hole saw, drill in the floor to access the cage nut. 10. Pry up on the cage surrounding the nut and slide the nut out. 11. Insert the new nut and bend the cage back into position to secure the nut. 12. Raise the vehicle and install the new bolt, torque to 163 Nm (120 ft. lbs.) 13. Lower the vehicle and vacuum all drill shavings. 14. Install the drain hole plug into the hole in the floor. Use a heat gun to seal the plug to the floor. 15. Center the mastic patch over the drain hole plug and install (Figure 2). To install, remove backing paper and apply firm even pressure across the entire patch to seal. 16. Position pad and carpet into proper location. 17. Remove prop holding brake and clutch pedal if applied. 18. Install the scuff plate and kick panel. 19. Install floor mat and reposition seat. 20. Repeat procedure for other side if needed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well - Creak/Rattle on Bumps Technical Service Bulletin # 23-47-97 Date: 970926 Front Foot Well - Creak/Rattle on Bumps NO: 23-47-97 GROUP: Body EFFECTIVE DATE: Sept. 26, 1997 SUBJECT: Creak/Rattle From Front Foot Well MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Creak/rattle from driver or passenger front foot well. The creak/rattle is more pronounced over bumps. DIAGNOSIS: Drive the vehicle over a bumpy road and listen for a creak/rattle in the foot well area. If creak/rattle is heard proceed with the repair procedure on the side that the noise is heard. If the side the creak/rattle is coming from cannot be determined by sound, torque each crossmember bolt to 163 Nm (120 ft lbs). If the bolt was at 163 Nm (120 ft.lbs), the torque is acceptable and no further action is needed on that side. If the torque was not at 163 Nm (120 ft. lbs), proceed to the Repair Procedure. PARTS REQUIRED: AR(1) 05011650AA Crossmember Bolt/Nut Repair Kit (Right) AR(1) 05011651AA Crossmember Bolt/Nut Repair Kit (Left) Each kit will include one of the following components: Cage Nut, Crossmember Bolt, Crossmember Mastic Patch Drain Plug Access Hole Template POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 13-30-01-90 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves drilling an access hole to replace the crossmember bolt and cage nut, then sealing the access hole. 1. Raise vehicle to gain access to the crossmember bolt. 2. Remove the crossmember bolt. 3. Lower the vehicle and open the door. 4. Slide the seat to the full rearward position. Remove the floor mat if so equipped. 5. Remove the scuff plate and kick panel. 6. Pull the carpet and pad away to access the floor. 7. Prop the clutch and brake pedal to make room for drilling (drivers side only). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 23-47-97 > Sep > 97 > Front Foot Well - Creak/Rattle on Bumps > Page 5800 8. Insert the template, mark and center punch the floor pan (Figure 1). 9. Using a drill and 70 mm (2-3/4") Dia hole saw, drill in the floor to access the cage nut. 10. Pry up on the cage surrounding the nut and slide the nut out. 11. Insert the new nut and bend the cage back into position to secure the nut. 12. Raise the vehicle and install the new bolt, torque to 163 Nm (120 ft. lbs.) 13. Lower the vehicle and vacuum all drill shavings. 14. Install the drain hole plug into the hole in the floor. Use a heat gun to seal the plug to the floor. 15. Center the mastic patch over the drain hole plug and install (Figure 2). To install, remove backing paper and apply firm even pressure across the entire patch to seal. 16. Position pad and carpet into proper location. 17. Remove prop holding brake and clutch pedal if applied. 18. Install the scuff plate and kick panel. 19. Install floor mat and reposition seat. 20. Repeat procedure for other side if needed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair Carpet: Service and Repair Carpet REMOVAL 1. Remove front seats. 2. Remove rear seat cushion. 3. Remove bolts holding rear seat belt lower anchors to floor. 4. Remove bolts holding front seat belt lower anchors to floor. 5. Remove bolts holding front seat belt buckles to floor. 6. Remove door sill trim covers. 7. Remove cowl trim covers. 8. Remove center floor console. 9. Remove lower fasteners from B-pillar trim panel. 10. Pull carpet from behind trim panel. 11. Fold carpet in half toward rear seat. 12. Remove carpet through rear door opening. INSTALLATION 1. Install carpet through rear door opening. 2. Unfold carpet. 3. Thick carpet behind trim panel. 4. Install lower fasteners holding B-pillar trim panel. 5. Install center floor console. 6. Install cowl trim covers. 7. Install door sill trim covers. 8. Install bolts holding front seat belt buckles to floor. 9. Install bolts holding front seat belt lower anchors to floor. 10. Install bolts holding rear seat belt lower anchors to floor. 11. Install rear seat cushion. 12. Install front seats. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 232497 > May > 97 > Center Console Latch - Broken Console: Customer Interest Center Console Latch - Broken NO: 23-24-97 GROUP: Body EFFECTIVE DATE: May 23, 1997 SUBJECT: Broken Center Console Latch MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Center console latch broken. DISCUSSION: If the center console latch (P/N 04775112AB) is broken, only the latch should be replaced without replacing the console lid. Illustration PARTS REQUIRED: 1 04775112AB Latch, Center Console REPAIR PROCEDURE: This bulletin involves replacing the center console latch. 1. Lift the center console lid. 2. Remove the two screws holding the latch to the lid and remove latch. 3. Install the new center console latch (P/N 04775112AB) and torque the two screws to 1.7 Nm (15 in.-lbs.) POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-41-40-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 232497 > May > 97 > Center Console Latch - Broken Console: All Technical Service Bulletins Center Console Latch - Broken NO: 23-24-97 GROUP: Body EFFECTIVE DATE: May 23, 1997 SUBJECT: Broken Center Console Latch MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: Center console latch broken. DISCUSSION: If the center console latch (P/N 04775112AB) is broken, only the latch should be replaced without replacing the console lid. Illustration PARTS REQUIRED: 1 04775112AB Latch, Center Console REPAIR PROCEDURE: This bulletin involves replacing the center console latch. 1. Lift the center console lid. 2. Remove the two screws holding the latch to the lid and remove latch. 3. Install the new center console latch (P/N 04775112AB) and torque the two screws to 1.7 Nm (15 in.-lbs.) POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-41-40-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Page 5818 Console: Service and Repair Floor Console REMOVAL 1. Fully apply parking brake. 2. Remove screw cover plugs over screws just rearward of cupholders. 3. Remove screws holding console to floor bracket just rearward of cupholders. 4. Open console storage compartment lid, if so equipped. 5. Remove screw cover plugs over screws near rear of console, if vehicle is equipped with a non-armrest console. 6. Remove screws holding console to floor bracket. 7. Remove shift lever knob, if vehicle is equipped with a manual transmission. 8. Lift console upward over gear selector and park brake handle. 9. Separate console from vehicle. INSTALLATION 1. Move floor console into position in vehicle. 2. Install screws holding console to floor brackets. 3. Install screw cover plugs. 4. Install shift lever knob, if vehicle is equipped with a manual transmission. 5. Release parking brake and close console storage compartment lid, if so equipped. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - 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. - 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, use proper and safe service procedures . Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: 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 disarm the system. NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). 1. Disconnect and isolate the battery negative (ground) cable. 2. 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 air-bag deployment and possible personal injury. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dash Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 5825 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming WARNING: Before attempting to diagnose, remove or install any airbag system components, first disconnect and isolate battery ground cable, then wait at least 2 minutes prior the performing any service. - Failure to do so may result in airbag deployment or personal injury. 1. Connect the scan tool to the Data Link connector which is located on the left side kick panel just above the hood release. 2. Turn the ignition key to the ON position. Exit vehicle with the scan tool. Use the latest version of the diagnostic cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative remote terminal. 4. Using the scan tool, read and record the active diagnostic trouble code data. 5. Read and record any stored diagnostic trouble codes. 6. Refer to Powertrain Management/Computers and Controls/Body Control Module if any diagnostic trouble codes are found in Step 4 and Step 5. 7. Erase stored diagnostic trouble codes if there are no active diagnostic trouble codes. If problems remain, diagnostic trouble codes will not erase. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. If the airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair REMOVAL 1. Remove screws holding sun visor to roof header panel. 2. Disengage wire connector from lighted vanity mirror, if so equipped. 3. Separate sun visors from vehicle. 4. Remove A-pillar trim covers. 5. Remove B-pillar trim panels, if vehicle is a 4 door. 6. Remove (upper) quarter panel trim panels. 7. Remove assist handles, if so equipped. 8. Remove sun visor hooks. 9. Remove coat hooks, if vehicle is a 4 door. 10. If vehicle is equipped with a sunroof; a. Open sunroof. Sunroof Opening Trim Welt b. Remove trim welt around sunroof opening. c. Remove sunroof switch pod. d. Disconnect sunroof switch pod wire connectors. e. Remove screw holding switch pod retainer to roof. 11. Remove push-in fastener at rear of headlining. 12. Disengage dome lamp wire connector, at rear of headlining. 13. Remove push-in fastener holding wiring to C-pillar. Headlining 14. Remove headlining through door opening. INSTALLATION 1. Position headlining in vehicle. 2. Install sun visor hooks. 3. Install coat hooks, if vehicle is a 4 door. 4. Install push-in fastener at rear of headlining. 5. install assist handles, if so equipped. 6. Install push-in fastener holding headliner wiring to C-pillar. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 5829 7. Engage dome lamp wire connector, at rear of headlining. 8. If vehicle is equipped with a sunroof; a. Install screw holding switch pod retainer to roof. b. Connect sunroof switch pod wire connectors. c. Install sunroof switch pod. Sunroof Opening Trim Welt d. Install trim welt around sunroof opening. e. Close sunroof. 9. Install (upper) quarter panel trim panel. 10. Install B-pillar trim panels, if vehicle is a 4 door. 11. Install A-pillar trim covers. 12. Install sun visors, lighted vanity mirror wire connector, if so equipped, and screws holding sun visors to roof header panel. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Trim Panel: Service and Repair A-Pillar Trim A-Pillar Trim REMOVAL 1. Remove instrument panel top cover. 2. Disengage clips holding trim to A-pillar. 3. Separate A-pillar trim from vehicle. 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. 4. Install instrument panel top cover. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim > Page 5834 Trim Panel: Service and Repair B-Pillar Trim-4 Door B-Pillar Trim REMOVAL 1. Remove bolt holding lower seat belt anchor to floor pan kick-up. 2. Remove shoulder belt height control knob. 3. Remove bolt holding turning loop to belt adjuster. 4. Remove access cover from B-pillar trim. 5. Disengage clips holding trim to B-pillar. 6. Feed seat belt turning loop and seat belt through trim panel. 7. Separate B-pillar trim from vehicle. INSTALLATION 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 holding turning loop to belt adjuster. 7. Install shoulder belt height control knob. 8. Install bolt holding lower seat belt anchor to floor pan kick-up. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim > Page 5835 Trim Panel: Service and Repair Cowl Side Trim Panel Side Cowl Trim REMOVAL 1. Disengage clips holding cowl trim to cowl side panel. 2. Separate cowl trim from vehicle. INSTALLATION 1. Position cowl trim panel to inner cowl panel. 2. Align locating pins on backside of cowl trim panel to mating holes in inner cowl panel. 3. Push clips on trim panel into slots in inner cowl panel. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim > Page 5836 Trim Panel: Service and Repair Door Opening Trim Welt Door Opening Trim Welt REMOVAL 1. Open door to gain access to trim welt. 2. Remove door sill trim panel. 3. Pull trim welt from door opening flange. INSTALLATION 1. Locate paint dot on backside of trim welt. 2. Position trim welt to vehicle with paint dot in the appropriate position. 3. Press trim welt onto door opening flange starting at the paint dot position. 4. Install door sill trim panel Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim > Page 5837 Trim Panel: Service and Repair A-Pillar Trim A-Pillar Trim REMOVAL 1. Remove instrument panel top cover. 2. Disengage clips holding trim to A-pillar. 3. Separate A-pillar trim from vehicle. 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. 4. Install instrument panel top cover. B-Pillar Trim-4 Door B-Pillar Trim REMOVAL 1. Remove bolt holding lower seat belt anchor to floor pan kick-up. 2. Remove shoulder belt height control knob. 3. Remove bolt holding turning loop to belt adjuster. 4. Remove access cover from B-pillar trim. 5. Disengage clips holding trim to B-pillar. 6. Feed seat belt turning loop and seat belt through trim panel. 7. Separate B-pillar trim from vehicle. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim > Page 5838 INSTALLATION 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 holding turning loop to belt adjuster. 7. Install shoulder belt height control knob. 8. Install bolt holding lower seat belt anchor to floor pan kick-up. Cowl Side Trim Panel Side Cowl Trim REMOVAL 1. Disengage clips holding cowl trim to cowl side panel. 2. Separate cowl trim from vehicle. INSTALLATION 1. Position cowl trim panel to inner cowl panel. 2. Align locating pins on backside of cowl trim panel to mating holes in inner cowl panel. 3. Push clips on trim panel into slots in inner cowl panel. Door Opening Trim Welt Door Opening Trim Welt REMOVAL 1. Open door to gain access to trim welt. 2. Remove door sill trim panel. 3. Pull trim welt from door opening flange. INSTALLATION Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim > Page 5839 1. Locate paint dot on backside of trim welt. 2. Position trim welt to vehicle with paint dot in the appropriate position. 3. Press trim welt onto door opening flange starting at the paint dot position. 4. Install door sill trim panel Door Sill Trim Door Sill Trim REMOVAL 1. Open door to gain access to sill trim. 2. Disengage clips holding sill trim to door sill and door opening flange. 3. Separate door sill trim from vehicle. 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. Lower Quarter Trim-4 Door Lower Quarter Trim REMOVAL 1. Remove upper quarter trim panel. 2. Remove rear seat cushion and back. 3. Disengage clips holding trim to lower quarter panel. 4. Remove seat belt from slot in trim panel. 5. Separate lower quarter trim from vehicle. INSTALLATION 1. Position lower quarter trim panel to vehicle. 2. Install seat belt to slot in trim panel. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim > Page 5840 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. Parcel Shelf Trim Parcel Shelf Trim 1. Remove upper quarter trim from one side of vehicle. 2. Remove rear seat cushion and back. 3. Remove bolts holding rear seat shoulder belt lower anchors to floor pan. 4. Disengage seat belt bezel from parcel shelf. 5. Separate parcel shelf trim from vehicle. 6. Reverse the preceding operation for installation. Quarter Trim Panel-2 Door Quarter Trim Panel REMOVAL 1. Remove rear seat cushion and back. 2. Slide lower seat belt anchor cover up the webbing to expose the belt. 3. Remove bolt holding lower seat belt anchor to floor. 4. Separate seat belt from floor. 5. Remove screw holding coat hook to top of quarter trim panel. 6. Disengage hidden clips holding quarter trim panel to inner quarter panel. 7. Separate trim from quarter panel. 8. Feed seat belt webbing through access bole in trim panel. 9. Separate quarter trim panel from vehicle. INSTALLATION 1. Feed seat belt webbing through access hole in trim panel. 2. Position trim panel near inner quarter panel. 3. Align locating pins on backside of trim panel to mating holes in inner quarter panel. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim > Page 5841 4. Push clips on trim panel into slots in inner quarter panel starting with the clips located near locating pins. 5. Install screw holding coat hook to top of quarter trim panel. 6. Install bolt securing seat belt anchor to floor. 7. Slide lower seat belt anchor cover down to cover anchor bolt. 8. Install rear seat cushion and seat back. Side View Mirror Trim Cover Side View Mirror Trim Cover 1. Disengage clips holding side view mirror cover to stanchion. 2. Separate mirror cover from vehicle. 3. Reverse the preceding operation for installation. Upper Quarter Trim Door Upper Quarter Trim REMOVAL 1. Disengage clips holding trim to upper quarter panel. 2. Separate 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. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair Door Lock Cylinder REMOVAL 1. Remove door trim panel and water shield. 2. Close door glass. 3. Disconnect door lock rod from latch. 4. Remove clip holding lock cylinder to door handle. 5. Pull lock cylinder from door handle. INSTALLATION 1. Push lock cylinder into door handle. 2. Install clip holding lock cylinder to door handle. 3. Connect door lock rod from latch. 4. Install door trim panel and water shield. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Description and Operation > Illuminated Entry Keyless Entry: Description and Operation Illuminated Entry CIRCUIT OPERATION When the RKE module determines a need for the interior lamps to be turned ON, the module energizes the relay connecting circuits M23 and Z2. The M23 circuit is the ground side for many of the vehicles interior lamps. The Z2 circuit connects to the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Description and Operation > Illuminated Entry > Page 5851 Keyless Entry: Description and Operation Panic Function CIRCUIT OPERATION When the operator activates the panic function of the system the RKE module grounds the appropriate relays connecting circuits F35 and L4 to feed the headlamps, and F35 to L7 to feed the parking lamps. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Description and Operation > Illuminated Entry > Page 5852 Keyless Entry: Description and Operation Power Door Locks CIRCUIT OPERATION Power for the Remote Keyless Entry (RKE) module is supplied from three sources. Power is supplied to the RKE module on circuit G5. This circuit is protected by a 5 Amp fuse located in cavity 11 of the fuse block. Power for the fuse is supplied from the ignition switch on circuit A21. This circuit is HOT in the START and RUN position. Power for the A21 circuit is supplied by circuit A1. This circuit is HOT at all times and is protected by a 30 Amp fuse located in the Power Distribution Center (PDC). Circuit F35 supplies battery voltage to the RKE module. This circuit is HOT at all times and is protected by a 20 Amp fuse located in cavity 3 of the fuse block. Power for the fuse is supplied on circuit A3. The A3 circuit is protected by a 40 Amp fuse located in the PDC. The F35 circuit is used to supply power for the contact side of several relays internal to the RKE module. Power is also supplied by circuit M1. This is the Ignition-Off Draw (IOD) circuit and is protected by a 10 Amp fuse located in cavity 13 of the Power Distribution Center (PDC). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Description and Operation > Illuminated Entry > Page 5853 Keyless Entry: Description and Operation Time Out Relay CIRCUIT OPERATION The time out relay is located in the fuse block and is used to control the ground path for various interior lamps. It will also turn the lamps OFF after a specified period of time, and works with the Remote Keyless Entry (RKE) system for illuminated entry. Circuit M2 connects to the relay and supplied a ground path through the door ajar switches. Circuit M1 is used to supply battery voltage to the relay. This circuit is produced by a 10 Amp fuse located in cavity 13 of the Power Distribution Center (PDC). Circuit M32 is connected from the relay to the various interior lamps and RKE module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Description and Operation > Illuminated Entry > Page 5854 Keyless Entry: Description and Operation Illuminated Entry CIRCUIT OPERATION When the RKE module determines a need for the interior lamps to be turned ON, the module energizes the relay connecting circuits M23 and Z2. The M23 circuit is the ground side for many of the vehicles interior lamps. The Z2 circuit connects to the instrument panel left center support. Panic Function CIRCUIT OPERATION When the operator activates the panic function of the system the RKE module grounds the appropriate relays connecting circuits F35 and L4 to feed the headlamps, and F35 to L7 to feed the parking lamps. Power Door Locks CIRCUIT OPERATION Power for the Remote Keyless Entry (RKE) module is supplied from three sources. Power is supplied to the RKE module on circuit G5. This circuit is protected by a 5 Amp fuse located in cavity 11 of the fuse block. Power for the fuse is supplied from the ignition switch on circuit A21. This circuit is HOT in the START and RUN position. Power for the A21 circuit is supplied by circuit A1. This circuit is HOT at all times and is protected by a 30 Amp fuse located in the Power Distribution Center (PDC). Circuit F35 supplies battery voltage to the RKE module. This circuit is HOT at all times and is protected by a 20 Amp fuse located in cavity 3 of the fuse block. Power for the fuse is supplied on circuit A3. The A3 circuit is protected by a 40 Amp fuse located in the PDC. The F35 circuit is used to supply power for the contact side of several relays internal to the RKE module. Power is also supplied by circuit M1. This is the Ignition-Off Draw (IOD) circuit and is protected by a 10 Amp fuse located in cavity 13 of the Power Distribution Center (PDC). Time Out Relay CIRCUIT OPERATION The time out relay is located in the fuse block and is used to control the ground path for various interior lamps. It will also turn the lamps OFF after a specified period of time, and works with the Remote Keyless Entry (RKE) system for illuminated entry. Circuit M2 connects to the relay and supplied a ground path through the door ajar switches. Circuit M1 is used to supply battery voltage to the relay. This circuit is produced by a 10 Amp fuse located in cavity 13 of the Power Distribution Center (PDC). Circuit M32 is connected from the relay to the various interior lamps and RKE module. Using Door Lock Switches CIRCUIT OPERATION Operation of the lock and unlock functions is the same as systems without Remote Keyless Entry (RKE). The only change between the systems is all of the lock and unlock circuits pass through the RKE module. Left Door Unlock CIRCUIT OPERATION When the operator selects left front UNLOCK the Remote Keyless Entry (RKE) module energizes the left front unlock relay connecting circuits F35 and P34. Circuit P34 connects from the module to the door lock motor. Ground for the motor is supplied on circuit P33 through a bus bar in the right switch to circuit P35. The P35 circuit connects from the switch to the LOCK-ALL relay in the RKE module. Ground is passed through the normally CLOSED contacts in the relay to the left door switch. Ground is passed through a bus bar in the switch to circuit Z8. This circuit terminates at the instrument panel left center support. Lock-All CIRCUIT OPERATION When the operator selects LOCK ALL the Remote Keyless Entry (RKE)module energizes the lock all relay connecting circuits F35 and P35. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Description and Operation > Illuminated Entry > Page 5855 Circuit P35 connects from the module to the passengers and drivers door switch, lock side. Power is passed through the bus bar in the passengers switch to circuit P33. This circuit connects to the LOCK side of the motors. Ground for the motors is supplied on circuit P34 through a bus bar in the right switch to circuit P36. The P36 circuit connects from the switch to the UNLOCK-ALL relay in the RKE module. Ground is passed through the normally CLOSED contacts in the relay to the left door switch. Ground is passed through a bus bar in the switch to circuit Z8. This circuit terminates at the instrument panel left center support. Unlock-All CIRCUIT OPERATION When the operator selects UNLOCK ALL the Remote Keyless Entry (RKE)module energizes the unlock all relay connecting circuits F35 and P36. Circuit P36 connects from the module to the passengers and drivers door switch, unlock side. Power is passed through the bus bar in the passengers switch to circuit P34. This circuit connects to the UNLOCK side of the motors. Ground for the motors is supplied on circuit P33 through a bus bar in the right switch to circuit P35. The P35 circuit connects from the switch to the LOCK-ALL relay in the RKE module. Ground is passed through the normally CLOSED contacts in the relay to the left door switch. Ground is passed through a bus bar in the switch to circuit Z8. This circuit terminates at the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Component Information > Description and Operation > Page 5856 Keyless Entry: Testing and Inspection - Check the 40 Amp fuse in the PDC. - Check the 15 Amp fuse in cavity 3 of the fuse block. - Check the grounding point on the instrument panel left center support brace. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Description and Operation > Left Door Switch Operation Power Door Lock Switch: Description and Operation Left Door Switch Operation Lock CIRCUIT OPERATION When the door lock switch is moved to the LOCK position, voltage is supplied on the P35 circuit to the bus bar located inside the right door switch, lock side. Battery voltage is passed through the switch to the P33 circuit to the door motors. Grounding is provided through the P34 circuit for all door motors back to the right door switch. The ground is passed through the bus bar internal to the switch, UNLOCK side, to the P36 circuit. The P36 circuit connects to the left front switch to a bus bar, internal to the switch, and then to the Z8 circuit. The Z8 circuit connects to its grounding point. Unlock CIRCUIT OPERATION When the switch is moved to the UNLOCK position, voltage is supplied on the P36 circuit to the right door switch, unlock side. The battery voltage is passed through the switch internal bus bar to the P34 circuit. The P34 circuit then connects to the door motors on the unlock side. Grounding for the UNLOCK function is provided by the P33 circuit. The P33 circuit connects back to the right door switch, LOCK side, and passes through the internal bus bar to the P35 circuit. The P35 circuit connects back to the left door switch, and passes through the switch to the Z8 circuit. The Z8 circuit goes to it's grounding point. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Description and Operation > Left Door Switch Operation > Page 5862 Power Door Lock Switch: Description and Operation Right Door Switch Operation Lock CIRCUIT OPERATION When the switch is moved to the LOCK position,voltage is supplied to the P33 circuit, and then to the door lock motors. The ground path is provided on the P34 circuit back to the right door switch. The ground is passed through the switch internal bus bar to the P36 circuit. The P36 circuit connects to the left door switch and through to the Z8 circuit. The Z8 circuit then connects to the grounding point at the left center instrument panel support. Unlock CIRCUIT OPERATION When the switch is moved to the UNLOCK position voltage is supplied to the P34 circuit from the switch to the door UNLOCK side of the motors. The grounding path is through the LOCK side of the motors, circuit P33, back to the switch. The ground continues through the internal bus bar of the switch on circuit P35 to the left door switch. At the left door switch, the ground passes through that switches internal bus bar to the Z8 grounding point. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Trunk Lock Cylinder 1. Remove trunk latch. 2. Remove clip holding trunk lock cylinder to trunk lid. 3. Pull lock cylinder from trunk lid. 4. Reverse the preceding operation for installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Description and Operation Power Mirror Switch: Description and Operation CIRCUIT OPERATION The power mirror switch has a right and left position. Moving the switch to either of these positions changes the voltage path internal to the switch (i.e.. changes polarity at the motors). When the switch is moved to the left position and mirror movement UP is selected, voltage is supplied through the P93 circuit and the ground path is through circuit P90. When the DOWN movement is selected the power and ground are reversed. If a left door mirror movement LEFT is selected voltage is supplied through the P95 circuit and the ground is passed through circuit P91. When the left door mirror RIGHT movement is selected the power and ground are reversed. When the switch is moved to the right position and mirror movement UP is selected, voltage is supplied through the P92 circuit and the ground path is through circuit P90. When the DOWN movement is selected the power and ground are reversed. If a right door mirror movement LEFT is selected voltage is supplied through the P94 circuit and the ground is passed through circuit P91. When the left door mirror RIGHT movement is selected the power and ground are reversed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Description and Operation > Page 5870 Power Mirror Switch: Testing and Inspection - Check the interior lamps 10 Amp fuse located in the PDC. - Circuit M1 supplies voltage to the radio, cargo lamp, underhood lamp, dome lamp, time delay relay, glove box lamp, and vanity lamps. Check for proper operation of these items. - Move the switch to its various positions and listen for the motors to click or try to move. Some movement or clicking indicated a poor connection or a mechanical problem with a mirror. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 23-25-00 > Jun > 00 > Paint - Surface Fogging or Whitening Paint: Customer Interest Paint - Surface Fogging or Whitening NUMBER: 23-25-00 GROUP: Body DATE: Jun. 30, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-05-98, DATED JANUARY 30, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Paint Fogging/Whitening OVERVIEW: This bulletin involves removal of a fogging or staining condition from any painted surface where moisture may be trapped under the clear coat. MODELS: 1996 - **2000** (JX) Sebring Convertible 1995 - **2000** (PL) Neon **2001 (PT) PT Cruiser** 1997 - **2001** (BR) Ram Truck SYMPTOM/CONDITION: Painted surfaces of the vehicle that are covered for extended periods of time with front end covers (Bras), transit films or magnetic signs may appear to have a white "milky" spot ** on dark colors, or a fogging, coffee colored spot lighter colors**. NOTE: WHEN USING A FRONT END COVER OR MAGNETIC SIGN, FOLLOW THE MANUFACTURER'S PRECAUTIONS. DIAGNOSIS: **Wash the affected area(s) with mild soap and water. Spot clean any area(s) to remove any difficult dirt, tar, bugs, etc. If paint fogging/whitening exist, run your hand over the surface, if no surface condition exists perform the following Repair Procedure**. EQUIPMENT REQUIRED **Heat Gun** REPAIR PROCEDURE: 1. **Place a heat gun approximately 100 to 150 mm (4 to 6 inches) from the effected area. A target surface temperature of 80° to 95° C. (180° to 200 °F.) is preferred. NOTE: DO NOT APPLY HEAT ABOVE 95° C. (200°F.) TO ANY PLASTIC PARTS. 2. Heat the effected area for approximately 2 to 4 minutes. The amount of time is dependent upon the size and shape of the affected area and the severity of the condition. NOTE: CIRCULATE THE HEAT GUN AROUND THE EFFECTED AREA. DO NOT ALLOW HEAT TO BE DIRECTED AT ONE AREA FOR TOO LONG, PAINT DAMAGE MAY OCCUR. 3. If this Repair Procedure does not correct the condition, color-coat paint repair will be required. NOTE: IF PAINT "FOGGING" DAMAGE WAS CAUSED BY A FRONT END COVER OR A MAGNETIC SIGN, THE OWNER SHOULD BE CAUTIONED AGAINST USING THAT PRODUCT, OR A SIMILAR PRODUCT THAT MAY CREATE THE PAINT "FOGGING".** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 23-25-00 > Jun > 00 > Paint - Surface Fogging or Whitening > Page 5880 Labor Operation No: 23-60-02-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-25-00 > Jun > 00 > Paint - Surface Fogging or Whitening Paint: All Technical Service Bulletins Paint - Surface Fogging or Whitening NUMBER: 23-25-00 GROUP: Body DATE: Jun. 30, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-05-98, DATED JANUARY 30, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Paint Fogging/Whitening OVERVIEW: This bulletin involves removal of a fogging or staining condition from any painted surface where moisture may be trapped under the clear coat. MODELS: 1996 - **2000** (JX) Sebring Convertible 1995 - **2000** (PL) Neon **2001 (PT) PT Cruiser** 1997 - **2001** (BR) Ram Truck SYMPTOM/CONDITION: Painted surfaces of the vehicle that are covered for extended periods of time with front end covers (Bras), transit films or magnetic signs may appear to have a white "milky" spot ** on dark colors, or a fogging, coffee colored spot lighter colors**. NOTE: WHEN USING A FRONT END COVER OR MAGNETIC SIGN, FOLLOW THE MANUFACTURER'S PRECAUTIONS. DIAGNOSIS: **Wash the affected area(s) with mild soap and water. Spot clean any area(s) to remove any difficult dirt, tar, bugs, etc. If paint fogging/whitening exist, run your hand over the surface, if no surface condition exists perform the following Repair Procedure**. EQUIPMENT REQUIRED **Heat Gun** REPAIR PROCEDURE: 1. **Place a heat gun approximately 100 to 150 mm (4 to 6 inches) from the effected area. A target surface temperature of 80° to 95° C. (180° to 200 °F.) is preferred. NOTE: DO NOT APPLY HEAT ABOVE 95° C. (200°F.) TO ANY PLASTIC PARTS. 2. Heat the effected area for approximately 2 to 4 minutes. The amount of time is dependent upon the size and shape of the affected area and the severity of the condition. NOTE: CIRCULATE THE HEAT GUN AROUND THE EFFECTED AREA. DO NOT ALLOW HEAT TO BE DIRECTED AT ONE AREA FOR TOO LONG, PAINT DAMAGE MAY OCCUR. 3. If this Repair Procedure does not correct the condition, color-coat paint repair will be required. NOTE: IF PAINT "FOGGING" DAMAGE WAS CAUSED BY A FRONT END COVER OR A MAGNETIC SIGN, THE OWNER SHOULD BE CAUTIONED AGAINST USING THAT PRODUCT, OR A SIMILAR PRODUCT THAT MAY CREATE THE PAINT "FOGGING".** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-25-00 > Jun > 00 > Paint - Surface Fogging or Whitening > Page 5886 Labor Operation No: 23-60-02-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 5887 Paint: By Symptom Technical Service Bulletin # 23-25-00 Date: 000630 Paint - Surface Fogging or Whitening NUMBER: 23-25-00 GROUP: Body DATE: Jun. 30, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-05-98, DATED JANUARY 30, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Paint Fogging/Whitening OVERVIEW: This bulletin involves removal of a fogging or staining condition from any painted surface where moisture may be trapped under the clear coat. MODELS: 1996 - **2000** (JX) Sebring Convertible 1995 - **2000** (PL) Neon **2001 (PT) PT Cruiser** 1997 - **2001** (BR) Ram Truck SYMPTOM/CONDITION: Painted surfaces of the vehicle that are covered for extended periods of time with front end covers (Bras), transit films or magnetic signs may appear to have a white "milky" spot ** on dark colors, or a fogging, coffee colored spot lighter colors**. NOTE: WHEN USING A FRONT END COVER OR MAGNETIC SIGN, FOLLOW THE MANUFACTURER'S PRECAUTIONS. DIAGNOSIS: **Wash the affected area(s) with mild soap and water. Spot clean any area(s) to remove any difficult dirt, tar, bugs, etc. If paint fogging/whitening exist, run your hand over the surface, if no surface condition exists perform the following Repair Procedure**. EQUIPMENT REQUIRED **Heat Gun** REPAIR PROCEDURE: 1. **Place a heat gun approximately 100 to 150 mm (4 to 6 inches) from the effected area. A target surface temperature of 80° to 95° C. (180° to 200 °F.) is preferred. NOTE: DO NOT APPLY HEAT ABOVE 95° C. (200°F.) TO ANY PLASTIC PARTS. 2. Heat the effected area for approximately 2 to 4 minutes. The amount of time is dependent upon the size and shape of the affected area and the severity of the condition. NOTE: CIRCULATE THE HEAT GUN AROUND THE EFFECTED AREA. DO NOT ALLOW HEAT TO BE DIRECTED AT ONE AREA FOR TOO LONG, PAINT DAMAGE MAY OCCUR. 3. If this Repair Procedure does not correct the condition, color-coat paint repair will be required. NOTE: IF PAINT "FOGGING" DAMAGE WAS CAUSED BY A FRONT END COVER OR A MAGNETIC SIGN, THE OWNER SHOULD BE CAUTIONED AGAINST USING THAT PRODUCT, OR A SIMILAR PRODUCT THAT MAY CREATE THE PAINT "FOGGING".** POLICY: Reimbursable within the provisions of the warranty. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 5888 TIME ALLOWANCE: Labor Operation No: 23-60-02-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Technical Service Bulletin # 23-25-00 Date: 000630 Paint - Surface Fogging or Whitening NUMBER: 23-25-00 GROUP: Body DATE: Jun. 30, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-05-98, DATED JANUARY 30, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS. SUBJECT: Paint Fogging/Whitening OVERVIEW: This bulletin involves removal of a fogging or staining condition from any painted surface where moisture may be trapped under the clear coat. MODELS: 1996 - **2000** (JX) Sebring Convertible 1995 - **2000** (PL) Neon **2001 (PT) PT Cruiser** 1997 - **2001** (BR) Ram Truck SYMPTOM/CONDITION: Painted surfaces of the vehicle that are covered for extended periods of time with front end covers (Bras), transit films or magnetic signs may appear to have a white "milky" spot ** on dark colors, or a fogging, coffee colored spot lighter colors**. NOTE: WHEN USING A FRONT END COVER OR MAGNETIC SIGN, FOLLOW THE MANUFACTURER'S PRECAUTIONS. DIAGNOSIS: **Wash the affected area(s) with mild soap and water. Spot clean any area(s) to remove any difficult dirt, tar, bugs, etc. If paint fogging/whitening exist, run your hand over the surface, if no surface condition exists perform the following Repair Procedure**. EQUIPMENT REQUIRED **Heat Gun** REPAIR PROCEDURE: 1. **Place a heat gun approximately 100 to 150 mm (4 to 6 inches) from the effected area. A target surface temperature of 80° to 95° C. (180° to 200 °F.) is preferred. NOTE: DO NOT APPLY HEAT ABOVE 95° C. (200°F.) TO ANY PLASTIC PARTS. 2. Heat the effected area for approximately 2 to 4 minutes. The amount of time is dependent upon the size and shape of the affected area and the severity of the condition. NOTE: CIRCULATE THE HEAT GUN AROUND THE EFFECTED AREA. DO NOT ALLOW HEAT TO BE DIRECTED AT ONE AREA FOR TOO LONG, PAINT DAMAGE MAY OCCUR. 3. If this Repair Procedure does not correct the condition, color-coat paint repair will be required. NOTE: IF PAINT "FOGGING" DAMAGE WAS CAUSED BY A FRONT END COVER OR A MAGNETIC SIGN, THE OWNER SHOULD BE Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 5889 CAUTIONED AGAINST USING THAT PRODUCT, OR A SIMILAR PRODUCT THAT MAY CREATE THE PAINT "FOGGING".** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-60-02-90 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair Sun Shade: Service and Repair NOTE: The numbered call-outs in the following service procedures refer the numbered parts found in the exploded view diagram. REMOVAL 1. Remove sunroof glass panel (4). Refer to procedure found in Sunroof/Service and Repair. 2. Slide sunshade (11) to full forward position. 3. Disengage slide blocks on one side of sunshade from sunshade guide (6). 4. Lift and pull sunshade out of opposite sunshade guide. INSTALLATION 1. Place sunshade with cloth side down and install one side's slide blocks into the track on the sunshade guide (6). 2. Slide the other side's slide blocks to fully inward position and insert them into the sunshade guide (6). 3. Verify that all four slide blocks are fully engaged in the sunshade guide (6). 4. Slide sunshade (11) fully rearward. 5. Install sunroof glass panel (4). Refer to procedure found in Sunroof/Service and Repair. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Service and Repair Sunroof / Moonroof Cable: Service and Repair NOTE: The numbered call-outs in the following service procedures refer the numbered parts found in the exploded view diagram. REMOVAL 1. Remove sunroof glass panel (4). Refer to procedure found in Sunroof/Service and Repair. 2. Cycle the sunroof mechanism to the full forward position. CAUTION: Do not remove sunroof drive motor unless sunroof mechanism is in the full forward position. 3. Remove sunroof drive motor (10). Refer to procedure found in Sunroof Drive Motor/Service and Repair. 4. Remove front locator (7 or 8) for appropriate sunroof cable. 5. Disengage sunroof cable from sunroof mechanism (9). 6. Pull sunroof cable from drive tube (2 or 3). INSTALLATION 1. Push sunroof cable through drive tube (2 or 3). 2. Engage sunroof cable into sunroof mechanism (9). 3. Install front locator (7 or 8) over sunroof cable. Moving the sunroof mechanism rearward slightly will ease locator installation. 4. Move sunroof to full forward position. 5. Install sunroof drive motor (10). 6. Install sunroof glass panel (5). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Motor: > 23-49-99 > Nov > 99 > Sunroof - Ratcheting Noise When Opening Or Closing Sunroof / Moonroof Motor: Customer Interest Sunroof - Ratcheting Noise When Opening Or Closing NUMBER: 23-49-99 GROUP: Body DATE: Nov. 12, 1999 SUBJECT: Sunroof Makes A Ratcheting Type Noise When Opening Or Closing OVERVIEW: This bulletin involves replacing the motor bracket drive tube locator. MODELS: 1996 - 1999 (PL) Neon SYMPTOM/CONDITION: The sunroof makes a ratcheting type noise while opening or closing. The noise is most noticeable at the full open or full closed position. The noise is caused by an oversized drive tube locator allowing the motor gear to override the drive tubes. DIAGNOSIS: While opening and closing the sunroof listen for the ratcheting noise, if the noise is heard perform the Repair Procedure. PARTS REQUIRED: 1 05016539AA Locator, Motor Bracket Drive Tube 4 04856501 Tie Strap REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the sunroof module following the procedure in the 1999 Neon Service Manual (Publication No. 81-270-9125) page 23-14. 2. Ensure that the sunroof module is in the full closed position and remove the sunroof motor from the sunroof module assembly. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Motor: > 23-49-99 > Nov > 99 > Sunroof - Ratcheting Noise When Opening Or Closing > Page 5906 3. With a 3 mm (.012 in.) drill bit remove the rivet holding the locator to the motor bracket (Figure 1). 4. Place the new locator over the drive tubes and secure with the rivet provided with the new locator. Make sure that the spring insert is in place under the bracket (Figure 2). 5. Install the motor. Ensure that the motor is positioned in the same place it was removed from. NOTE: WHEN INSTALLING THE SUNROOF MODULE INSURE THAT THE DRAIN TUBE CLAMPS ARE INSTALLED IN THE POSITION THEY WERE REMOVED FROM DURING DISASSEMBLY. USE A TIE STRAP OR EQUIVALENT TO SECURE THE DRIVE TUBES IN THE SAME LOCATIONS THE CLAMPS WERE REMOVED FROM DURING DISASSEMBLY. 6. Install the sunroof module following the procedure in the 1999 Neon Service Manual (Publication No. 81-270-9125) page 23-14. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-30-64-92 1.7 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Motor: > 23-49-99 > Nov > 99 > Sunroof - Ratcheting Noise When Opening Or Closing Sunroof / Moonroof Motor: All Technical Service Bulletins Sunroof - Ratcheting Noise When Opening Or Closing NUMBER: 23-49-99 GROUP: Body DATE: Nov. 12, 1999 SUBJECT: Sunroof Makes A Ratcheting Type Noise When Opening Or Closing OVERVIEW: This bulletin involves replacing the motor bracket drive tube locator. MODELS: 1996 - 1999 (PL) Neon SYMPTOM/CONDITION: The sunroof makes a ratcheting type noise while opening or closing. The noise is most noticeable at the full open or full closed position. The noise is caused by an oversized drive tube locator allowing the motor gear to override the drive tubes. DIAGNOSIS: While opening and closing the sunroof listen for the ratcheting noise, if the noise is heard perform the Repair Procedure. PARTS REQUIRED: 1 05016539AA Locator, Motor Bracket Drive Tube 4 04856501 Tie Strap REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the sunroof module following the procedure in the 1999 Neon Service Manual (Publication No. 81-270-9125) page 23-14. 2. Ensure that the sunroof module is in the full closed position and remove the sunroof motor from the sunroof module assembly. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Motor: > 23-49-99 > Nov > 99 > Sunroof - Ratcheting Noise When Opening Or Closing > Page 5912 3. With a 3 mm (.012 in.) drill bit remove the rivet holding the locator to the motor bracket (Figure 1). 4. Place the new locator over the drive tubes and secure with the rivet provided with the new locator. Make sure that the spring insert is in place under the bracket (Figure 2). 5. Install the motor. Ensure that the motor is positioned in the same place it was removed from. NOTE: WHEN INSTALLING THE SUNROOF MODULE INSURE THAT THE DRAIN TUBE CLAMPS ARE INSTALLED IN THE POSITION THEY WERE REMOVED FROM DURING DISASSEMBLY. USE A TIE STRAP OR EQUIVALENT TO SECURE THE DRIVE TUBES IN THE SAME LOCATIONS THE CLAMPS WERE REMOVED FROM DURING DISASSEMBLY. 6. Install the sunroof module following the procedure in the 1999 Neon Service Manual (Publication No. 81-270-9125) page 23-14. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-30-64-92 1.7 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > Page 5913 Sunroof / Moonroof Motor: Service and Repair NOTE: The numbered call-outs in the following service procedures refer the numbered parts found in the exploded view diagram. CAUTION: Do not cycle the sunroof drive motor prior to installation. The drive motor is shipped in the closed position. The sunroof vent position is programmed into the drive motor and is dependent upon the drive motor closed position. If the drive motor and the sunroof mechanism are not both in the closed position, the sunroof vent height will not be correct. REMOVAL 1. Remove headlining until the sunroof drive motor (10) can be accessed. 2. If the drive motor is to be reused, cycle the sunroof to the full forward position. 3. Disconnect wire harness connector from motor. 4. Remove the three screws attaching drive motor to sunroof module bracket. 5. Separate drive motor (10) from bracket. INSTALLATION 1. With the aid of a helper, hold the sunroof glass panel in the closed position and engage the drive motor (10) into the sunroof drive cables. 2. Install screws holding drive motor to bracket. 3. Connect wire harness to drive motor. 4. Install headlining. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Description and Operation Sunroof / Moonroof Switch: Description and Operation CIRCUIT OPERATION When the operator selects tilt OPEN circuit F1O is connected to circuit Q43. Circuit Q43 connects from the switch to the CLOSED vent limit switch in the sunroof module. The voltage is passed through the switch to circuit Q46. The Q46 circuit connects from the limit switch to the slide switch OPEN side. Power is passed through the switch to the Q41 circuit, then to the power sunroof motor. Ground is provided on circuit Q42 from the motor to the slide switch CLOSE side. The ground is passed through the bus bar in the switch to circuit Q45. The Q45 circuit connects from the slide switch to the tilt switch CLOSE side. Ground is passed through the switch to the Z5 circuit and to ground. When the operator selects the VENT CLOSE function, power and ground are reversed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair Sunroof / Moonroof Track: Service and Repair NOTE: The numbered call-outs in the following service procedures refer the numbered parts found in the exploded view diagram. SUNROOF GUIDE AND MECHANISM ASSEMBLY Removal 1. Remove sunroof glass panel (4). Refer to procedure in Sunroof/Service and Repair. 2. Remove front locator (7 or 8). 3. Disengage cable from mechanism (9). 4. Remove screws holding sunroof guide (5) and mechanism (9) assembly to sunroof module. 5. Lift assembly from module. 6. Rotate assembly to disengage wind deflector (13) from assembly Installation 1. Engage wind deflector (13) into guide (5) and mechanism (9) assembly 2. Position assembly onto module and install screws holding assembly to sunroof module. 3. Engage drive cable to mechanism. 4. Install front locator (7 or 8). It may ease installation to move sunroof mechanism slightly rearward. 5. Install sunroof glass panel. Refer to procedure found in Sunroof/Service and Repair. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair Sunroof / Moonroof Windguard: Service and Repair NOTE: The numbered call-outs in the following service procedures refer the numbered parts found in the exploded view diagram. REMOVAL 1. Open sunroof to full open position. 2. Pull one end of wind deflector flap out of the wind deflector beam (13). 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 guide (5). 6. Repeat for other corner piece. INSTALLATION 1. Hold corner piece vertically and push tab down through hole in guide (5). 2. Rotate corner piece inward and place tab under roof flange. 3. Connect corner piece to wind deflector beam (13). 4. Install wind deflector flap into wind deflector beam. 5. Repeat for other corner piece. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5928 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5929 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5930 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5931 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 5932 TIME ALLOWANCE: FAILURE CODE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest for Seat Back: > 236795 > Nov > 95 > Seat Back Release Knob - Comes Loose Seat Back: Customer Interest Seat Back Release Knob - Comes Loose NO: 23-67-95 GROUP: Body DATE: Nov. 3, 1995 SUBJECT: Seat Back Release Knob Comes Loose MODELS: 1995-1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 2 DOOR VEHICLES BUILT PRIOR TO 10-12-95 (MDH 10-12-XX). SYMPTOM/CONDITION: Plastic release knob falls off or housing may be cracked on seat back release. Knob may pull off when seat back release is being used or may be kicked off on entry/exit of rear seats. PARTS REQUIRED: 2 4773524 Knob and Housing, Inertia Release 1 4467709 Bond All Gel, Mopar REPAIR PROCEDURE: This bulletin involves the replacement of the inertia release knob and housing with revised parts. 1. If knob and housing are still attached to the lever, remove knob and housing by pulling straight out. The knob and housing should come loose by hand. 2. Apply the Mopar Bond All Gel (P/N 4467709) around the tip of the lever. Insure that the small pin on lever is covered with the bonding agent. Figure 1 3. Install the new knob and housing (P/N 4773524) immediately after applying the bond. Allow the repair to cure for one hour before use. 4. Repeat the procedure for the other side. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest for Seat Back: > 236795 > Nov > 95 > Seat Back Release Knob - Comes Loose > Page 5941 Labor Operation No: 23-42-20-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 236795 > Nov > 95 > Seat Back Release Knob - Comes Loose Seat Back: All Technical Service Bulletins Seat Back Release Knob - Comes Loose NO: 23-67-95 GROUP: Body DATE: Nov. 3, 1995 SUBJECT: Seat Back Release Knob Comes Loose MODELS: 1995-1996 (PL) Neon NOTE: THIS BULLETIN APPLIES TO 2 DOOR VEHICLES BUILT PRIOR TO 10-12-95 (MDH 10-12-XX). SYMPTOM/CONDITION: Plastic release knob falls off or housing may be cracked on seat back release. Knob may pull off when seat back release is being used or may be kicked off on entry/exit of rear seats. PARTS REQUIRED: 2 4773524 Knob and Housing, Inertia Release 1 4467709 Bond All Gel, Mopar REPAIR PROCEDURE: This bulletin involves the replacement of the inertia release knob and housing with revised parts. 1. If knob and housing are still attached to the lever, remove knob and housing by pulling straight out. The knob and housing should come loose by hand. 2. Apply the Mopar Bond All Gel (P/N 4467709) around the tip of the lever. Insure that the small pin on lever is covered with the bonding agent. Figure 1 3. Install the new knob and housing (P/N 4773524) immediately after applying the bond. Allow the repair to cure for one hour before use. 4. Repeat the procedure for the other side. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 236795 > Nov > 95 > Seat Back Release Knob - Comes Loose > Page 5947 Labor Operation No: 23-42-20-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Left Door Switch Operation Power Door Lock Switch: Description and Operation Left Door Switch Operation Lock CIRCUIT OPERATION When the door lock switch is moved to the LOCK position, voltage is supplied on the P35 circuit to the bus bar located inside the right door switch, lock side. Battery voltage is passed through the switch to the P33 circuit to the door motors. Grounding is provided through the P34 circuit for all door motors back to the right door switch. The ground is passed through the bus bar internal to the switch, UNLOCK side, to the P36 circuit. The P36 circuit connects to the left front switch to a bus bar, internal to the switch, and then to the Z8 circuit. The Z8 circuit connects to its grounding point. Unlock CIRCUIT OPERATION When the switch is moved to the UNLOCK position, voltage is supplied on the P36 circuit to the right door switch, unlock side. The battery voltage is passed through the switch internal bus bar to the P34 circuit. The P34 circuit then connects to the door motors on the unlock side. Grounding for the UNLOCK function is provided by the P33 circuit. The P33 circuit connects back to the right door switch, LOCK side, and passes through the internal bus bar to the P35 circuit. The P35 circuit connects back to the left door switch, and passes through the switch to the Z8 circuit. The Z8 circuit goes to it's grounding point. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Left Door Switch Operation > Page 5953 Power Door Lock Switch: Description and Operation Right Door Switch Operation Lock CIRCUIT OPERATION When the switch is moved to the LOCK position,voltage is supplied to the P33 circuit, and then to the door lock motors. The ground path is provided on the P34 circuit back to the right door switch. The ground is passed through the switch internal bus bar to the P36 circuit. The P36 circuit connects to the left door switch and through to the Z8 circuit. The Z8 circuit then connects to the grounding point at the left center instrument panel support. Unlock CIRCUIT OPERATION When the switch is moved to the UNLOCK position voltage is supplied to the P34 circuit from the switch to the door UNLOCK side of the motors. The grounding path is through the LOCK side of the motors, circuit P33, back to the switch. The ground continues through the internal bus bar of the switch on circuit P35 to the left door switch. At the left door switch, the ground passes through that switches internal bus bar to the Z8 grounding point. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation Power Mirror Switch: Description and Operation CIRCUIT OPERATION The power mirror switch has a right and left position. Moving the switch to either of these positions changes the voltage path internal to the switch (i.e.. changes polarity at the motors). When the switch is moved to the left position and mirror movement UP is selected, voltage is supplied through the P93 circuit and the ground path is through circuit P90. When the DOWN movement is selected the power and ground are reversed. If a left door mirror movement LEFT is selected voltage is supplied through the P95 circuit and the ground is passed through circuit P91. When the left door mirror RIGHT movement is selected the power and ground are reversed. When the switch is moved to the right position and mirror movement UP is selected, voltage is supplied through the P92 circuit and the ground path is through circuit P90. When the DOWN movement is selected the power and ground are reversed. If a right door mirror movement LEFT is selected voltage is supplied through the P94 circuit and the ground is passed through circuit P91. When the left door mirror RIGHT movement is selected the power and ground are reversed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 5957 Power Mirror Switch: Testing and Inspection - Check the interior lamps 10 Amp fuse located in the PDC. - Circuit M1 supplies voltage to the radio, cargo lamp, underhood lamp, dome lamp, time delay relay, glove box lamp, and vanity lamps. Check for proper operation of these items. - Move the switch to its various positions and listen for the motors to click or try to move. Some movement or clicking indicated a poor connection or a mechanical problem with a mirror. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation Sunroof / Moonroof Switch: Description and Operation CIRCUIT OPERATION When the operator selects tilt OPEN circuit F1O is connected to circuit Q43. Circuit Q43 connects from the switch to the CLOSED vent limit switch in the sunroof module. The voltage is passed through the switch to circuit Q46. The Q46 circuit connects from the limit switch to the slide switch OPEN side. Power is passed through the switch to the Q41 circuit, then to the power sunroof motor. Ground is provided on circuit Q42 from the motor to the slide switch CLOSE side. The ground is passed through the bus bar in the switch to circuit Q45. The Q45 circuit connects from the slide switch to the tilt switch CLOSE side. Ground is passed through the switch to the Z5 circuit and to ground. When the operator selects the VENT CLOSE function, power and ground are reversed. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information > Technical Service Bulletins > Competition Package Front Fascia - Information Air Dam: Technical Service Bulletins Competition Package Front Fascia - Information NO: 23-22-98 GROUP: Body DATE: Jun. 12, 1998 SUBJECT: Competition Package (Sales Code ACR) Front Fascia Information MODELS: 1995 - 1998 (PL) Neon NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT WITH THE COMPETITION PACKAGE (SALES CODE ACR) ONLY. DISCUSSION: Neon's built with the corn petition package (sales code ACR) are built with the same front fascia as a Sport, Expresso and RT models. The sport model front fascia includes holes for fog lamps. However on the competition package the fog lamps are not installed to allow for additional air flow during racing. If a replacement is necessary to a front fascia on a vehicle equipped with the competition package, it is important that the correct fascia with the fog lamp openings be installed. If a customer requests that fog lamps be added at their expense, they should be advised that if the vehicle is modified from original equipment it may then be illegal for some competition situations. The addition of fog lamps is not a warrantable issue. POLICY: Information Only Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair Front Door Weatherstrip: Service and Repair FRONT DOOR INNER BELT WEATHERSTRIP Removal 1. Remove door trim panel. Front Door Inner Belt Weatherstrip 2. Separate weatherstrip from door. Installation 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. WINDOW INNER BELT STABILIZER Removal 1. Remove door trim panel. 2. Remove nut holding inner belt stabilizer to door panel. Inner Belt Stabilizer 3. Separate inner belt stabilizer from door. Installation Reverse the preceding operation. Adjust inner belt stabilizer against glass with enough tension to allow free up and down movement. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Page 5970 Outer Belt Weatherstrip FRONT DOOR OUTER BELT WEATHERSTRIP Removal 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. 3. Separate outer belt weatherstrip from vehicle. Installation 1. Starting at leading edge of door, press weatherstrip onto door. 2. Operate window and check for interference Rear Door Inner Belt Weatherstrip REAR DOOR INNER BELT WEATHERSTRIP Removal 1. Remove door trim panel. 2. Pull weatherstrip from top of door panel. 3. Separate weatherstrip from door. Installation 1. Place inner belt weatherstrip in position on door. 2. Push down on weatherstrip to engage channel to door panel. 3. Install door trim panel. REAR DOOR OUTER BELT WEATHERSTRIP Removal 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Page 5971 Outer Belt Weatherstrip 3. Separate outer belt weatherstrip from vehicle. 4. Reverse the preceding operation for installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair Rear Door Weatherstrip: Service and Repair FRONT DOOR INNER BELT WEATHERSTRIP Removal 1. Remove door trim panel. Front Door Inner Belt Weatherstrip 2. Separate weatherstrip from door. Installation 1. Push down on weatherstrip to engage channel to door panel. 2. Install door trim panel. WINDOW INNER BELT STABILIZER Removal 1. Remove door trim panel. 2. Remove nut holding inner belt stabilizer to door panel. Inner Belt Stabilizer 3. Separate inner belt stabilizer from door. Installation Reverse the preceding operation. Adjust inner belt stabilizer against glass with enough tension to allow free up and down movement. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Page 5975 Outer Belt Weatherstrip FRONT DOOR OUTER BELT WEATHERSTRIP Removal 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. 3. Separate outer belt weatherstrip from vehicle. Installation 1. Starting at leading edge of door, press weatherstrip onto door. 2. Operate window and check for interference Rear Door Inner Belt Weatherstrip REAR DOOR INNER BELT WEATHERSTRIP Removal 1. Remove door trim panel. 2. Pull weatherstrip from top of door panel. 3. Separate weatherstrip from door. Installation 1. Place inner belt weatherstrip in position on door. 2. Push down on weatherstrip to engage channel to door panel. 3. Install door trim panel. REAR DOOR OUTER BELT WEATHERSTRIP Removal 1. Open door glass. 2. Pull upward at rear end of outer belt weatherstrip. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Page 5976 Outer Belt Weatherstrip 3. Separate outer belt weatherstrip from vehicle. 4. Reverse the preceding operation for installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection Fig. 79 Stop Lamp Switch 1. Remove stop lamp switch assembly and disconnect connector. 2. Using a suitable ohmmeter, ensure there is continuity between switch terminals Nos. 5 and 6. When plunger is depressed, there should be continuity between terminals Nos. 1 and 2 and between terminals Nos. 3 and 4. 3. If above results are not obtained, switch is defective or out of adjustment. Switch is adjusted by pulling out plunger to end of travel which is approximately 3/4 inch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection > Page 5981 Brake Switch (Cruise Control): Service and Repair 1. Depress brake pedal while rotating switch in a counterclockwise direction approximately 30° degrees. Pull switch out of bracket and disconnect wiring harness connector. Fig. 79 Stop Lamp Switch 2. Reverse procedure to install ensuring to pull switch plunger out to full length of travel and align switch with index key on bracket during installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Locations Speed Control Servo Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Locations > Page 5985 Speed Control Servo Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Locations > Page 5986 Speed Control Servo: Testing and Inspection 1. Turn ignition switch to ON position without starting engine. 2. Activate speed control ON switch. Fig. 13 Servo Harness Connector 3. Disconnect 4-way electrical connector and vacuum harness at servo. 4. Connect a jumper wire from pin 2 of the servo to pin 2 of the wire connector. 5. Ground pins 1, 3 and 4 in the servo connector 6. Connect a suitable hand held vacuum pump to the vacuum nipple of the servo and apply 10-15 inches of vacuum. 7. Ensure throttle cable pulls in and holds as long as long as vacuum pump is connected. After one minute, ensure cable is still holding. If cable does not hold, replace servo. 8. Disconnect pin 3 from ground. Cable should return to rest position. If cable does not return, replace servo. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Locations > Page 5987 Speed Control Servo: Service and Repair 1. Disconnect battery cables, then remove battery thermoguard, battery hold down and battery. 2. Remove power distribution center from back of battery tray. 3. Disconnect speed control cable from throttle body. 4. Remove screw holding support strut to front of battery tray. 5. Remove top battery tray fasteners. 6. Slide tray up and disconnect speed control servo wiring and vacuum harness from servo. 7. Remove attaching nuts and then speed control assembly from bottom of battery tray. 8. Reverse procedure to install ensuring servo wiring connector points toward the left front corner of vehicle when battery tray is installed. Torque nuts to 60 inch lbs. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Description and Operation Speed Control Switch: Description and Operation Name of Code: Speed Control Switch Always High When Monitored: With the ignition key on. Set Condition: An open condition is detected in the speed control on/off switch circuit. Theory of Operation: This circuit is monitored continuously by the PCM whenever the ignition is turned on. The trouble code sets if the voltage in this circuit is above 4.7 volts for more than 1 second. Possible Causes: - Mux switch circuit shorted to power - Mux switch circuit open - Open on/off switch - PCM failure Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Description and Operation > Page 5991 Speed Control Switch: Testing and Inspection 1. Remove ON/OFF speed control switch assembly and disconnect connector. 2. Using a suitable ohmmeter, ensure there is no continuity between switch terminals. Press the OFF button and ohmmeter should read 0-0.5 ohms. Press the ON button and ohmmeter should read 15,245-15,555 ohms. If resistance does not fall within these values, replace switch. 3. Remove RESUME/SET/CANCEL speed control switch assembly and disconnect connector. 4. Using a suitable ohmmeter, ensure there is no continuity between switch terminals. Press the SET button and ohmmeter should read 2910-2970 ohms. Press the RESUME button and ohmmeter should read 6580-6750 ohms. Press the CANCEL button and ohmmeter should read 900-920 ohms. If resistance does not fall within these values, replace switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Description and Operation > Page 5992 Speed Control Switch: Service and Repair The speed control switches are mounted in the steering wheel and wired through the clock spring device under the air bag module. 1. Ensure ignition switch is in OFF position. 2. Remove screws from each side of switch, then gently pull switch away from steering wheel assembly using a rocking motion. 3. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection Fig. 79 Stop Lamp Switch 1. Remove stop lamp switch assembly and disconnect connector. 2. Using a suitable ohmmeter, ensure there is continuity between switch terminals Nos. 5 and 6. When plunger is depressed, there should be continuity between terminals Nos. 1 and 2 and between terminals Nos. 3 and 4. 3. If above results are not obtained, switch is defective or out of adjustment. Switch is adjusted by pulling out plunger to end of travel which is approximately 3/4 inch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection > Page 5997 Brake Switch (Cruise Control): Service and Repair 1. Depress brake pedal while rotating switch in a counterclockwise direction approximately 30° degrees. Pull switch out of bracket and disconnect wiring harness connector. Fig. 79 Stop Lamp Switch 2. Reverse procedure to install ensuring to pull switch plunger out to full length of travel and align switch with index key on bracket during installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Description and Operation Speed Control Switch: Description and Operation Name of Code: Speed Control Switch Always High When Monitored: With the ignition key on. Set Condition: An open condition is detected in the speed control on/off switch circuit. Theory of Operation: This circuit is monitored continuously by the PCM whenever the ignition is turned on. The trouble code sets if the voltage in this circuit is above 4.7 volts for more than 1 second. Possible Causes: - Mux switch circuit shorted to power - Mux switch circuit open - Open on/off switch - PCM failure Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Description and Operation > Page 6001 Speed Control Switch: Testing and Inspection 1. Remove ON/OFF speed control switch assembly and disconnect connector. 2. Using a suitable ohmmeter, ensure there is no continuity between switch terminals. Press the OFF button and ohmmeter should read 0-0.5 ohms. Press the ON button and ohmmeter should read 15,245-15,555 ohms. If resistance does not fall within these values, replace switch. 3. Remove RESUME/SET/CANCEL speed control switch assembly and disconnect connector. 4. Using a suitable ohmmeter, ensure there is no continuity between switch terminals. Press the SET button and ohmmeter should read 2910-2970 ohms. Press the RESUME button and ohmmeter should read 6580-6750 ohms. Press the CANCEL button and ohmmeter should read 900-920 ohms. If resistance does not fall within these values, replace switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Description and Operation > Page 6002 Speed Control Switch: Service and Repair The speed control switches are mounted in the steering wheel and wired through the clock spring device under the air bag module. 1. Ensure ignition switch is in OFF position. 2. Remove screws from each side of switch, then gently pull switch away from steering wheel assembly using a rocking motion. 3. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation The Antilock Brake System (ABS) warning lamp located on the instrument cluster will turn on when the CAB detects a condition which results in a shutdown of the ABS function. The ABS warning lamp will turn on for approximately four-five seconds after the ignition key is switched to the ON position. During this time the CAB runs a system self test. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Ammeter Gauge > Component Information > Description and Operation Ammeter Gauge: Description and Operation This LED operates independently of the gauge indicator and monitors system voltage. The LED will alert the driver of the following three charging system potential malfunctions: 1. A discharging condition, caused by excessive electrical demand on charging system (engine at idle RPM). 2. A weak or defective battery with ignition switch in On position (before ignition switch is moved to Start position). 3. A weak or defective battery with minimum demand on charging system, while vehicle is being used in stop and go driving (intermittent LED illumination occurring). Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Ammeter Gauge > Component Information > Description and Operation > Page 6010 Ammeter Gauge: Testing and Inspection Use tester tool No. C-3826, or equivalent, when diagnosing systems. Proceed with the following test only if the battery and charging system are functioning properly. Turn ignition switch to the On position and turn on headlights, windshield wipers and stoplights. This will cause excessive demand on charging system activating the LED immediately or within approximately one minute. If the LED does not light, there is a malfunction in the system. If LED lights, run engine at approximately 2000 RPM, LED should stop emitting light. If the LED continues to emit light there is a malfunction in the system. In all cases of system malfunctions, the complete gauge must be replaced. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation Audible Warning Device: Description and Operation CIRCUIT OPERATION The key-in chime is used to indicate to the operator that the key is in the ignition with the drivers door OPEN. If the key is in the ignition and the drivers door is OPEN, a ground path is completed from the G26 circuit at the cluster, through the CLOSED key-in switch, to the G16 circuit and terminating at the door ajar switch which is case grounded. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > ABS Warning Lamp Circuit Operation Brake Warning Indicator: Description and Operation ABS Warning Lamp Circuit Operation CIRCUIT OPERATION The ABS warning lamp is an output from the Controller Anti Lock Brake (CAB) and the Anti-lock Brakes System (ABS) relay box. It is used to alert the operator of a problem in the ABS system. The G19 circuit from the CAB and the ABS system relay is used to detect a problem. If a problem is detected, the CAB grounds the G19 circuit and illuminates the lamp in the instrument cluster. Circuit G19 is also an output of the CAB to the ABS system relay contact side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > ABS Warning Lamp Circuit Operation > Page 6018 Brake Warning Indicator: Description and Operation Brake Warning Lamp Circuit Operation CIRCUIT OPERATION The Brake Warning Indicator lamp is used to alert the operator of a problem with the vehicles braking system. The lamp illuminates when the ignition switch is turned to START position to perform a self check. There are two switches used in this system and they are wired in parallel form. A parking brake switch located on the parking brake mechanism will illuminate the lamp if the normally OPEN switch is CLOSED. This switch is case grounded. The other switch used is the brake warning lamp switch. This switch is normally OPEN. When the brake system pressure is below a predetermined level the switch CLOSES and completes a path to ground from the G9 circuit at the cluster, through the switch, to the left headlamp ground. If the vehicle is built for use in Canada the parking brake switch is used for the Daytime Running Lamp Module (DRL). See: Lighting and Horns/Daytime Running Lamp/Daytime Running Lamp Control Unit/Description and Operation Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Page 6019 Brake Warning Indicator: Testing and Inspection - Check the 5 Amp fuse in cavity 11 of the fuse block. - Check the 4 Amp fuse in cavity 12 of the fuse block. - Check the Ignition-Off Draw fuse in the PDC. - Check for a good ground at the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Diagrams Instrument Panel Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Diagrams > Page 6023 Charge Lamp/Indicator: Description and Operation CIRCUIT OPERATION The Charge Indicator lamp is used to alert the operator that the charging system voltage has fallen below the normal operating range. This circuit is controlled by the Powertrain Control Module (PCM). When the PCM determines a problem, it grounds the G12 circuit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6028 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6029 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6030 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6031 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6032 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6033 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6034 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6035 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6036 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6037 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6038 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6039 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6040 Cigarette Lighter: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6041 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6042 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6043 Cigarette Lighter: Electrical Diagrams Horn/Cigar Lighter NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6044 Cigarette Lighter: Description and Operation CIRCUIT OPERATION The cigar lighter is powered by a 40 Amp fuse located in the Power Distribution Center (PDC). There is also a 15 Amp fuse located in cavity 1 of the fuse block dedicated for the cigar lighter. When the operator presses the lighter, contacts inside of the lighter element CLOSE and voltage flows through the heating element to ground. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 6045 Cigarette Lighter: Testing and Inspection - Check the 40 Amp fuse located in the PDC. - Check the 15 Amp fuse located in the fuse block. - Check for a good ground at the instrument panel left center support. - Check the cigar lighter element. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - 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. - 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, use proper and safe service procedures . Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: 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 disarm the system. NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). 1. Disconnect and isolate the battery negative (ground) cable. 2. 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 air-bag deployment and possible personal injury. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dash Panel <--> [Dashboard / Instrument Panel] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 6052 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming WARNING: Before attempting to diagnose, remove or install any airbag system components, first disconnect and isolate battery ground cable, then wait at least 2 minutes prior the performing any service. - Failure to do so may result in airbag deployment or personal injury. 1. Connect the scan tool to the Data Link connector which is located on the left side kick panel just above the hood release. 2. Turn the ignition key to the ON position. Exit vehicle with the scan tool. Use the latest version of the diagnostic cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative remote terminal. 4. Using the scan tool, read and record the active diagnostic trouble code data. 5. Read and record any stored diagnostic trouble codes. 6. Refer to Powertrain Management/Computers and Controls/Body Control Module if any diagnostic trouble codes are found in Step 4 and Step 5. 7. Erase stored diagnostic trouble codes if there are no active diagnostic trouble codes. If problems remain, diagnostic trouble codes will not erase. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. If the airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove upper and lower steering column shrouds. 3. Remove combination switch mounting screws. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: Customer Interest Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 6064 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps Improper Operation Door Switch: All Technical Service Bulletins Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps Improper Operation > Page 6070 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair Driver/Vehicle Information Display: Service and Repair 1. Disconnect battery ground cable. 2. Remove instrument panel top cover and cluster bezel. 3. Remove four screws attaching cluster housing to base panel. 4. Pull cluster rearward to disconnect from base panel. 5. Remove cluster assembly. 6. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation Fuel Gauge: Description and Operation CIRCUIT OPERATION The fuel level gauge is connected to the fuel pump module on the G4 circuit. The fuel pump module contains the fuel pump and a variable resistor for the gauge. Grounding for the fuel pump module is provided on the Z2 circuit and terminates at the left rear wheel house. The logic driven gauge moves in response to the measured resistance of the fuel tank sending unit. The fuel level sensor contains a variable resistor. As the position of the float arm on the level sensor changes, the resistor changes the current flow through the fuel gauge circuit. A change in current flow alters the magnetic field in the fuel gauge which changes the pointer position. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > General Description Fuel Gauge Sender: Description and Operation General Description Fig. 10 Level Sensor Diagnosis OPERATION The fuel gauge sending unit is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and two variable resistors (tracks). These two tracks are used to send two different electrical signals. One is used for fuel gauge operation and the other is for OBD II emission requirements. Track 1 fuel gauge operation: As the fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge on the instrument panel to read full. As the fuel level decreases, the float and arm move down. This increases the sending unit resistance, causing the fuel gauge on the instrument panel to read empty Track 2-OBD II emission requirements: A variable voltage signal is sent to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes if the fuel level in the tank is less than 15 percent of its rated capacity. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > General Description > Page 6081 Fuel Gauge Sender: Description and Operation Related Trouble Codes and Set Conditions Fuel Level Sending Unit Volts Too High Name of Code: Fuel Level Sending Unit Volts Too High When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes above a calculated value. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel systems monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Open sensor signal circuit - Fuel level sending unit failure - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Fuel Level Sending Unit Volts Too Low Name of Code: Fuel Level Sending Unit Volts Too Low When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes below 0.10 volts. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel system monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Sensor signal circuit shorted to ground - Fuel level sending unit failure - Loss of fuel ignition switch output voltage - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Page 6082 Fuel Gauge Sender: Testing and Inspection Fig. 10 Level Sensor Diagnosis This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. To test the level sensor, connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector. Move the float lever to the positions shown in the resistance chart. Record the resistance at each point. Replace the level sensor if the resistance is not within specifications. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Page 6083 Fuel Gauge Sender: Service and Repair Fig. 21 Fuel Pump/Level Sensor Electrical Connector NOTE: Remove fuel pump module prior to beginning this procedure. REMOVAL 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector. Fig. 22 Wire Terminal Locking Wedge 2. Pull off blue locking wedge. Fig. 23 Wire Terminal Locking Finger 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Page 6084 Fig. 24 Removing Wires From Connector 4. Push level sensor signal and ground terminals out of the connector. Fig. 25 Loosening Level Sensor 5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Fig. 26 Level Sensor Removal/Installation 6. Push level sensor down slightly. - Ensure tab at bottom of sensor locks in place. 7. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 8. Install locking wedge on connector. 9. Push connector up into bottom of fuel pump module electrical connector. 10. Install fuel pump module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Headlamp Reminder Indicator > Component Information > Description and Operation Headlamp Reminder Indicator: Description and Operation CIRCUIT OPERATION The headlamp ON chime is used to indicate to the operator that the headlamps or parking lamps are ON when the drivers door is OPEN. If the lamps are ON and the drivers door is opened, a ground path is completed from the G26 circuit at the cluster through the headlamp switch, to the G16 circuit and ending at the door ajar switch. The door ajar switch is case grounded. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) 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 WARNINGS: - 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. - 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, use proper and safe service procedures . Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: 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 disarm the system. NOTE: Access and record all fault (trouble) codes prior to disarming the Supplemental Restraint System (SRS). 1. Disconnect and isolate the battery negative (ground) cable. 2. 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 air-bag deployment and possible personal injury. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 6094 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming WARNING: Before attempting to diagnose, remove or install any airbag system components, first disconnect and isolate battery ground cable, then wait at least 2 minutes prior the performing any service. - Failure to do so may result in airbag deployment or personal injury. 1. Connect the scan tool to the Data Link connector which is located on the left side kick panel just above the hood release. 2. Turn the ignition key to the ON position. Exit vehicle with the scan tool. Use the latest version of the diagnostic cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative remote terminal. 4. Using the scan tool, read and record the active diagnostic trouble code data. 5. Read and record any stored diagnostic trouble codes. 6. Refer to Powertrain Management/Computers and Controls/Body Control Module if any diagnostic trouble codes are found in Step 4 and Step 5. 7. Erase stored diagnostic trouble codes if there are no active diagnostic trouble codes. If problems remain, diagnostic trouble codes will not erase. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. If the airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Refer to Powertrain Management/Computers and Controls/Body Control Module to diagnose the problem. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation Low Fuel Lamp/Indicator: Description and Operation When the gauge indicator shows approximately 1/8 tank of fuel remaining, the LED will light, alerting the driver to a low fuel condition. When the gauge indicator shows engine temperature to be 240-260°F, the LED will light, alerting the driver to an overheating condition. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams Instrument Panel Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Page 6101 Malfunction Indicator Lamp: Description and Operation Fig.1 Data Link (Diagnostic) Connector OPERATION As a functional test, the Malfunction Indicator Lamp (MIL) illuminates at key-on before engine cranking. Whenever the Powertrain Control Module (PCM) sets a Diagnostic Trouble Code (DTC) that affects vehicle emissions, it illuminates the MIL. If a problem is detected, the PCM sends a message over the CCD Bus to the instrument cluster to illuminate the lamp. The PCM illuminates the MIL only for DTC's that affect vehicle emissions. The MIL stays on continuously when the PCM has entered a Limp-In mode or identified a failed emission component. The MIL remains on until the DTC is erased. Also, the MIL either flashes or illuminates continuously when the PCM detects active engine misfire. Addifionally the PCM may reset (turn off) the MIL when one of the following occur: PCM does not detect the malfunction for 3 consecutive trips (except misfire and Fuel system Monitors). - PCM does not detect a malfuction while performing three successive engine misfire or fuel system tests. The PCM performs these tests while the engine is operating within ±375 RPM of and within 10% of the load of the operating condition at which the malfunction was first detected. CIRCUIT OPERATION The Check Engine lamp (Malfunction Indicator Lamp) illuminates when the ignition switch is in the ON position and prior to starting the vehicle. The lamp will turn off after the vehicle is started. If while the vehicle is running a problem is detected in the engine control system the lamp is illuminated. This is accomplished by the Powertrain Control Module (PCM) grounding the G3 circuit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation Odometer: Description and Operation CIRCUIT OPERATION The speedometer and odometer receive their information on the G7 circuit from the Vehicle Speed Sensor (VSS). This circuit also provides a signal to the Powertrain Control Module (PCM). Logic internal to the cluster steps the odometer at a high rate to indicate the proper mileage. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation Fig.3 Gauge LED Locations The fuel, temperature and ammeter gauges are equipped with a Light Emitting Diode (LED) mounted in each of the gauge dials. This diode will illuminate and alert the driver that the system is malfunctioning. The electronic sensor circuit is mounted on the gauge housing. The printed circuit board is permanently attached and is not serviceable. If the LED is malfunctioning, the gauge and the printed circuit board must be replaced as an assembly. The oil pressure warning switch, mounted on the engine, is controlled by engine oil pressure. When engine oil pressure is high (normal operating condition) the switch is held in the Off position allowing no current to flow to the oil pressure warning lamp on the instrument panel. When engine oil pressure is low, the switch is in the On position allowing current to flow to the oil pressure warning lamp on the instrument panel causing the instrument panel to be illuminated. When the switch is in the Off position, it completes the circuit for the electric choke heater. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation CIRCUIT OPERATION The low oil pressure lamp is used to indicate to the operator that the engine oil pressure has dropped below a predetermined pressure. Power for the lamp is provided on the G5 circuit which also powers the other warning lamps. When the oil pressure is low the normally OPEN oil pressure switch CLOSES completing a path to ground. The oil pressure switch is case grounded to the engine block. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Testing and Inspection Parking Brake Warning Switch: Testing and Inspection In the START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) to circuit A41. A 30 Amp fuse protects circuits A1 and A41. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation CIRCUIT OPERATION The fasten seat belt indicator is used with the warning chime to indicate to the operator to fasten the seat belt. There is a switch located in the drivers side B-pillar that is normally OPEN with the seat belt buckled. If the seat belt is not buckled the switch CLOSES and a ground path is completed from the G10 circuit to the Z1 circuit. This will illuminate the lamp in the instrument cluster. When the ignition switch is moved to the START position the lamp will illuminate. Logic internal to the instrument cluster determines the length of time. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove upper and lower steering column shrouds. 3. Remove combination switch mounting screws. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: Customer Interest Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 6129 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: All Technical Service Bulletins Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 6135 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > General Description Fuel Gauge Sender: Description and Operation General Description Fig. 10 Level Sensor Diagnosis OPERATION The fuel gauge sending unit is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and two variable resistors (tracks). These two tracks are used to send two different electrical signals. One is used for fuel gauge operation and the other is for OBD II emission requirements. Track 1 fuel gauge operation: As the fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge on the instrument panel to read full. As the fuel level decreases, the float and arm move down. This increases the sending unit resistance, causing the fuel gauge on the instrument panel to read empty Track 2-OBD II emission requirements: A variable voltage signal is sent to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes if the fuel level in the tank is less than 15 percent of its rated capacity. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > General Description > Page 6140 Fuel Gauge Sender: Description and Operation Related Trouble Codes and Set Conditions Fuel Level Sending Unit Volts Too High Name of Code: Fuel Level Sending Unit Volts Too High When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes above a calculated value. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel systems monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Open sensor signal circuit - Fuel level sending unit failure - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Fuel Level Sending Unit Volts Too Low Name of Code: Fuel Level Sending Unit Volts Too Low When Monitored: Ignition on. Set Condition: The fuel level sensor signal circuit voltage at the PCM goes below 0.10 volts. Theory of Operation: The voltage at the fuel level sending unit sends a variable voltage to the powertrain control module to indicate fuel level. The purpose of this feature is to prevent false setting of misfire and fuel system monitor codes when the vehicle is operating at low fuel levels. Possible Causes: - Sensor signal circuit shorted to ground - Fuel level sending unit failure - Loss of fuel ignition switch output voltage - Instrument cluster printed circuit board failure - Powertrain control module failure - Connector wires - Connector terminals Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 6141 Fuel Gauge Sender: Testing and Inspection Fig. 10 Level Sensor Diagnosis This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. To test the level sensor, connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector. Move the float lever to the positions shown in the resistance chart. Record the resistance at each point. Replace the level sensor if the resistance is not within specifications. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 6142 Fuel Gauge Sender: Service and Repair Fig. 21 Fuel Pump/Level Sensor Electrical Connector NOTE: Remove fuel pump module prior to beginning this procedure. REMOVAL 1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector. Fig. 22 Wire Terminal Locking Wedge 2. Pull off blue locking wedge. Fig. 23 Wire Terminal Locking Finger 3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 6143 Fig. 24 Removing Wires From Connector 4. Push level sensor signal and ground terminals out of the connector. Fig. 25 Loosening Level Sensor 5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Fig. 26 Level Sensor Removal/Installation 6. Push level sensor down slightly. - Ensure tab at bottom of sensor locks in place. 7. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position. 8. Install locking wedge on connector. 9. Push connector up into bottom of fuel pump module electrical connector. 10. Install fuel pump module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Testing and Inspection Parking Brake Warning Switch: Testing and Inspection In the START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) to circuit A41. A 30 Amp fuse protects circuits A1 and A41. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation CIRCUIT OPERATION The PRNDL lamp receives power on the E2 circuit from the 4 Amp fuse located in the fuse block in cavity 12. The fuse receives power from the headlamp switch. Circuit E2 also powers the ash receiver lamp. When the headlamp switch is moved to the PARK or ON position, current flows through the fuse to the PRNDL lamp. The ground for the lamp is supplied on the Z3 circuit, and terminates at the instrument panel left center support. This circuit is also spliced in with the ash receiver lamp, the ignition switch lamp, and the glove box lamp. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation Speedometer Head: Description and Operation OPERATION The vehicle is equipped with electronically driven speedometer and odometer assemblies. A signal is sent from a transmission-mounted vehicle speed sensor to the speedometer circuitry through the wiring harness. The speedometer has two main parts: the indicator head and the speedometer drive cable. When the speedometer fails to indicate speed or mileage, the cable or housing is probably broken. CIRCUIT OPERATION The speedometer and odometer receive their information on the G7 circuit from the vehicle speed sensor. This circuit also provides a signal to the Powertrain Control Module (PCM). Logic internal to the instrument cluster adjusts the position of the gauge pointer to the correct vehicle speed using the signal on the G7 circuit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams Instrument Panel Connector Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Page 6156 Tachometer: Description and Operation CIRCUIT OPERATION The tachometer is connected to the Powertrain Control Module (PCM) on the G21 circuit. It uses solid state circuity to decode the ignition pulses received from the PCM to adjust the gauge pointer to the proper position. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation CIRCUIT OPERATION The temperature gauge is connected to the engine coolant temperature sensor on the G20 circuit. The engine coolant temperature sensor for the gauge is a combination unit. One side of the unit is used for the Powertrain Control Module (PCM) and the other side for the cluster. The sending unit is case grounded to the engine. The logic driven gauge moves in response to the measured resistance of the engine coolant temperature sending unit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Transmission Connections Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6167 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6168 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6169 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6170 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6171 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6172 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6173 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6174 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6175 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6176 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6177 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6178 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6179 Backup Lamp Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6180 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6181 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6182 Rear Lighting (Part 1 Of 3) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Page 6183 Backup Lamp Switch: Testing and Inspection Back-Up Lamp Switch The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 1. To test the switch, remove the wiring connector from the switch and test for continuity between the two outside pins. Continuity should only exist with the transaxle in the REVERSE position. 2. No continuity should exist from either pin to the transaxle case. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > Automatic Transmission Backup Lamp Switch: Service and Repair Automatic Transmission Park/Neutral Starting and Back-Up Lamp Switch Removal 1. Place a suitable container under the switch to catch fluid when switch is removed. 2. Unscrew switch from transaxle case allowing fluid to drain into container. 3. Move selector lever to PARK, then NEUTRAL position and inspect to see the switch operating lever fingers are centered in the switch opening. Installation 1. Crew the switch with a new seal into the transaxle case and tighten to 33 Nm (24 ft. lbs.). 2. Test switch with a test lamp. 3. Add fluid to transaxle to bring up to proper level. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > Automatic Transmission > Page 6186 Backup Lamp Switch: Service and Repair Manual Transmission Back-Up Lamp Switch Removal 1. Lift vehicle on hoist. 2. From the bottom side of the vehicle, remove wiring connector from the switch. 3. Unscrew switch from the transaxle. Installation 1. To install, follow removal procedure in reverse order. Teflon tape or equivalent must be used on the switch threads. Tighten switch to 24 Nm (18 ft. lbs.). CAUTION: Do not overtighten switch. 2. Confirm back-up lamps are functioning properly following installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Description and Operation > Stop Lamp Description Brake Lamp: Description and Operation Stop Lamp Description CIRCUIT OPERATION Circuit F32 in the Power Distribution Center (PDC) feeds the stop lamps. Circuit F32 connects to the stop lamp switch. A 15 Amp fuse in the PDC protects circuit F32. When the operator presses the brake pedal, the stop lamp switch CLOSES and connects circuit F32 to circuit L50. Circuit L50 connects to the multi-function switch and supplies voltage to the L62 and L63 circuits. Circuit L63 powers the left stop lamp. Circuit L63 powers the left stop lamp. Circuit L50 splices to power the CHMSL lamp. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Description and Operation > Stop Lamp Description > Page 6191 Brake Lamp: Description and Operation Stop Lamp Ground Circuit CIRCUIT OPERATION Circuit Z1 provides ground for the stop lamps, CHMSL lamp, and the stop lamp switch. The Z1 circuit has more than one grounding point. It also supplies ground path for the tail lamps, parking lamps, headlamps, side marker lamps, rear license plate lamp, back-up lamps and turn signals Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Description and Operation > Page 6192 Brake Lamp: Testing and Inspection - Check for blown fuses in circuit F32 (in PDC). - Check for continuity across the stop lamp switch when it is CLOSED. - For rear lighting on the left side of the vehicle, the Z1 circuit grounding point is in the left rear wheel well. - For rear lighting on the right side of the vehicle, the Z1 circuit grounding point is in the right rear wheel well. - For the stop lamp switch, the Z1 circuit grounding point is in the left front inner fender shield. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6196 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6197 Brake Light Switch: Service and Repair 1. Disconnect battery ground cable. 2. Depress brake pedal and rotate switch counterclockwise approximately 30°. 3. Pull switch rearward and remove from mounting bracket. 4. Disconnect wire connector from switch. 5. Pull switch plunger head out until ratchet sound stops. 6. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Description and Operation Ash Tray Lamp: Description and Operation CIRCUIT OPERATION The ash receiver lamp receives power on the E2 circuit from the 4 Ampfuse located in the fuse block in cavity 12. The fuse receives power from the headlamp switch. Circuit E2, which is HOT at all times, also powers the Transmission Range Indicator (PRNDL) lamp. When the headlamp switch is moved to the PARK or ON position, current flows through the fuse to the ash receiver lamp. The ground for the lamp is supplied on the Z3 circuit, and terminates at the instrument panel left center support. This circuit is also spliced in with the PRNDL lamp, the ignition switch lamp, and the glove box lamp. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Description and Operation Glove Box Lamp: Description and Operation CIRCUIT OPERATION The glove box lamp receives power on the M1 circuit from the 10 Ampfuse located in the Power Distribution Center (PDC). A switch, wired in series after the lamp, CLOSES when the glove box door is opened, and completes a path to ground on the Z3 circuit. The Z3 circuit is spliced in with the ash receiver lamp, PRNDL lamp, and the time delay relay. The Z3 circuit terminates at the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Description and Operation Daytime Running Lamp Control Unit: Description and Operation CIRCUIT OPERATION On vehicles built for sale in Canada, the headlamps operate, at reduced intensity, when the ignition switch is in the RUN position and the parking brake switch is OPEN. In the Power Distribution Center (PDC), a bus bar connected to battery voltage feeds circuit A1. In the RUN position, the ignition switch connects circuit A1 to circuit A21. A 30 Amp fuse in the PDC, protects circuits A1 and A21. Circuit A21 connects to a bus bar in the fuse block. The bus bar in the fuse block feeds circuit G5 through a 5 Amp fuse in cavity 11. Circuit G5 is powered only when the ignition switch is in the RUN position. Circuit G9 connects to the DRL module. The G9 circuit splices to the brake warning switch, park brake switch and instrument cluster brake warning bulb. Circuit L20 from the headlamp and dimmer switch supplies battery voltage to the DRL module at all times. Circuit A3 from the PDC feeds circuit L20. A 40 Amp fuse in the PDC protects the A3 circuit. From the DRL module, circuit L4 powers the LOW beams of the left and right headlamps. The DRL controls the power to circuit L4. Circuit L4 connects to cavity 10 of the Daytime Running Lamp (DRL) module. Circuit L3 feeds the high beams of the headlamps. When the operator flashes the headlamps with the stalk of the multi-function switch, the DRL senses voltage on circuit L3. When it senses voltage on circuit L3, the DRL module stops supplying power to the low beams on circuit L4. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove upper and lower steering column shrouds. 3. Remove combination switch mounting screws. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Description and Operation Battery Discharge Protection Relay: Description and Operation Halo Lamp/Time Delay Relay CIRCUIT OPERATION The time delay relay is used to allow a time-ON function for the ignition switch halo lamp. Power for the relay is received on the M1 circuit from the 10 Amp fuse located in the Power Distribution Center (PDC). This is the Ignition-Off Draw (IOD) fuse and HOT at all times. When a door is OPENED, or the headlamp switch is moved to the dome lamp position, a ground path is provided for the relay on the M2 circuit. This energizes the relay, CLOSING the contacts. When the relay contacts are CLOSED, power is provided through the relay to the M50 circuit. The M50 circuit supplies current to the ignition switch lamp in the steering column. Ground for the lamp is provided on the Z3 circuit. This circuit splices with the glove box lamp, the ash receiver lamp, and the PRNDL lamp. The Z3 circuit terminates at the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Description and Operation Dome Lamp: Description and Operation CIRCUIT OPERATION The dome lamp receives power from the 10 Amp fuse located in the Power Distribution Center on the M1 circuit. This circuit is HOT at all times and the Ignition-Off Draw (IOD) fuse. The ground path for the lamp is provided in two different ways. One way is through the door ajar switches and the time out relay. Circuit M2 connects to all the door ajar switches from the time out relay. The switches are case-grounded to the body when a door is OPENED, the plunger in the switch CLOSES, completing a path to ground. The second ground path is through the headlamp switch. Circuit M32 is spliced in with the time out relay. Then the operator turns the headlamp switch to the dome lamp ON position, a ground path is provided through the switch on the Z1 circuit. This ground terminates at the instrument panel left center support. On vehicles equipped with Remote Keyless Entry (RKE) the M32 circuit is spliced to the RKE module. This allows the lamp to be turned ON when a valid signal is received by the RKE module from the transmitter. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: Customer Interest Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 6226 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: All Technical Service Bulletins Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 6232 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Component Information > Description and Operation > Fog Lamp Fog/Driving Lamp: Description and Operation Fog Lamp CIRCUIT OPERATION The fog lamps will operate only when the head lamp switch is in the ON position, and the operator has selected LOW beam operation. When the head lamps are in high beam operation, the fog lamps will not operate. Circuit A3 from the Power Distribution Center supplies (PDC) voltage to a bus bar in the fuse block. Circuit F61 is one of four circuits that the bus bar Feeds and is protected by a 10 Amp fuse in cavity 4. Circuit F61 connects to the fog lamp switch. The fog lamp switch contains a relay that supplies. Voltage to the fog lamps. Circuit L4 from the multi-function switch supplies voltage to the coil side of the relay (only when the headlamps operate on LOW beam). Circuit F61 supplies voltage to the contact side of the relay. During LOW beam headlamp operation when the fog lamp switch contacts CLOSE, circuit F61 connects to circuit L39. Circuit L39 feeds right and left fog lamp. Circuit L39 also feeds the green L.E.D. in the switch that illuminates during fog 1 Amps operation. When the headlamp switch is in the PARK or ON position, circuit E1 from the headlamp switch supplies voltage for circuit E2. Circuit E2 contains a 4 Amp fuse in cavity 12 of the fuse block, and powers the bulb in the fog lamp switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Component Information > Description and Operation > Fog Lamp > Page 6237 Fog/Driving Lamp: Description and Operation Ground Circuit CIRCUIT OPERATION Although circuit Z1 provides the ground path for the fog lamps, the circuit has different grounding points for each lamp. For the left fog lamp the grounding point is the left side of the radiator closure panel. For the right fog lamp the grounding point is the right fender side shield. Circuit Z3 supplies the ground path for the fog lamp switch. The grounding point for the headlamp switch is the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Component Information > Description and Operation > Page 6238 Fog/Driving Lamp: Testing and Inspection - Circuit Z1 also supplies ground for side marker lamps, turn signals, parking lamps and headlamps. - Circuit A3 from the Power Distribution Center (PDC) supplies voltage to the headlamp switch for circuit L2. - Circuit F33 from the fuse block supplies voltage Lo the headlamp switch for circuit E1. Circuit A3 Prom the PDC supplies voltage to a bus bar in the fuse block that feeds the F33 circuit. Fuse 2, in the Fuse block, protects the F33 circuit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Fuse/Fuse Block (Part 1 Of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation > Ground Circuit Hazard Warning Flasher: Description and Operation Ground Circuit CIRCUIT OPERATION Circuit Z3 provides ground for the instrument cluster indicator lamps. The termination point for circuit Z3 is the instrument panel left center support. Circuit Z1 provides ground for all the turn signal/ hazard lamps, although the it has different grounding points for each circuit. Circuit Z2 provides the ground path for the combination flashing unit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation > Ground Circuit > Page 6245 Hazard Warning Flasher: Description and Operation Hazard Flasher CIRCUIT OPERATION Circuit L9 from the Power Distribution Center (PDC) supplies battery voltage for the hazard flashers. A 10 Amp fuse in the PDC protects circuit L9. Circuit L9 connects to the multi-function switch. With the hazard flashers ON, the multi-function switch connects circuits L9 and L55. Circuit L55 feeds the combination flashing unit. Circuit Z2 provides ground for the flashing unit. From the flashing unit, circuit L32 connects to the multi-function switch. With the hazard flashers ON, the multi-function switch connects circuit L32 to circuits L60, L61, L62, and L63. Circuit L6O supplies voltage to the right front turn signal/hazard lamp. The L6O circuit splices to the instrument cluster to power the right indicator lamp. Circuit L61 supplies voltage to the left front turn signal/hazard lamp. The L61 circuit splices to the instrument cluster to power the left indicator lamp. Circuit L62 supplies voltage to the right rear turn signal/hazard flasher/stop lamp. Circuit L63 supplies voltage to the left rear turn signal/hazard/ flasher/stop lamp. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation > Page 6246 Hazard Warning Flasher: Testing and Inspection - For the left front turn signal/hazard flasher lamp the Z1 circuit grounding point is the left side of the radiator closure panel. - For the right front turn signal/hazard flasher lamp the Z1 circuit grounding point is in the right tender side shield. - For the left rear turn signal/hazard flasher/stop lamp the Z1 circuit grounding point is in the left rear wheel well. - For the right rear turn signal/hazard flasher/stop lamp the Z1 circuit grounding point is in the right rear wheel well. - Circuit Z1 also supplies ground for the headlamps, parking lamps, rear license plate lamp, back-up lamps and side marker lamps. - The grounding point for circuit Z2 is the instrument panel right center support. Circuit Z2 supplies ground for the combination flashing unit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch In OFF or PARKING Lamp Position Headlamp Switch: Description and Operation Headlamp Switch In OFF or PARKING Lamp Position CIRCUIT OPERATION Circuit A3 originates in the Power Distribution Center (PDC) and supplies battery voltage for the headlamp switch. A 40 Amp fuse protects the A3 circuit. The headlamp switch has an internal 24 Amp circuit breaker that connects circuit A3 to either the L2 or L20 circuits, depending on switch position. In the OFF and PARK positions the headlamp switch feeds the L20 circuit that connects to the multi-function switch. Circuit L20 powers the high beam circuit when the operator flashes the headlamps with the turn signal stalk of the multi-function switch. When the operator flashes the headlamps with the stalk, the multi-function switch connects the L20 circuit to the L3 circuit. The L3 circuit feeds the high beam of the headlamps. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch In OFF or PARKING Lamp Position > Page 6252 Headlamp Switch: Description and Operation Headlamp Switch In ON Position CIRCUIT OPERATION When the headlamp switch is in the ON position, it connects the A3 circuit from the PDC to circuit L2. Circuit L2 connects to the multi-function switch and feeds the L4 circuit (for low beam operation). The L4 circuit connects to a bus bar in the fuse block. Circuits L43 and L44 connect to the bus bar in fuse block and power the low beam headlamps. Circuit L43 supplies voltage to the left headlamp. Circuit L44 supplies voltage to the right headlamp. Both the L43 and L44 circuits have separate 10 Amp fuses located in fuse block. Fuse 17 protects circuit L43, and fuse 18 protects circuit L44. When the operator selects high beam operation with the turn signal stalk of the multi-function switch, circuit L2 connects to the L3 circuit, Circuit L3 powers high beam operation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Page 6253 Headlamp Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove steering column cover and liner. 3. Remove three screws securing headlamp switch mounting plate to instrument panel. 4. Pull headlamp switch assembly rearward from instrument panel opening. 5. Disconnect two electrical connectors from switch. Headlamp Switch Replacement 6. Depress button on bottom of switch, then pull control knob out of switch. 7. Unsnap headlamp switch bezel from mounting plate for access to retaining nut. 8. Remove retaining nut and mounting plate from switch. 9. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Description and Operation Hi-Beam Indicator Lamp: Description and Operation CIRCUIT OPERATION The High Beam Indicator Lamp is used to indicate to the operator that the high beam headlamps are ON. Power is supplied to the cluster on the L3 circuit for vehicles without Daytime Running Lamps (DRL), or the G34 circuit for vehicles with DRL. Ground is provided on the Z3 circuit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Power Distribution (Part 1 Of 2) Fig. 15 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6261 Horn Relay: Testing and Inspection The content of this article reflects changes called for in TSB 26-03-96. Horn Relay 1. Remove horn relay. 2. Using ohmmeter, test for continuity between ground and circuit 65 of horn relay. a. When the horn switch is not depressed, no continuity should be present. b. Continuity to ground when the horn switch is pdepressed. c. If continuity is not correct, repair the horn switch or wiring as necessary. 3. Insert a jumper wire between circuit 63 and 66 of the Power Distribution Center. a. If horn sounds, replace relay. b. If horn does not sound, install horn relay and refer to Horn Test. 4. Using voltmeter, test voltage at: a. Circuit 62 and 66 test for battery voltage from fuse C to body ground. b. If voltage is incorrect, repair as necessary. Refer to wiring diagrams. 5. Check relay for 70-75 ohms resistance from terminal 85 to 86. If resistance not OK, replace relay. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6262 Horn Relay: Service and Repair The content of this article reflects changes called for in TSB 26-03-96. Horn Relay 1. Remove power Distribution Center cover and locate the horn relay. 2. Remove the horn relay. Installation For installation, reverse above procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations Horn Switch: Locations The horn switch is part of the Driver Airbag Module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 6266 Horn Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO Restraint Systems / Air Bag Systems FOR STEERING WHEEL OR COLUMN REMOVAL PROCEDURES. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 6267 Horn Switch: Description and Operation The content of this article reflects changes called for in TSB 26-03-96. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO Restraint Systems / Air Bag Systems FOR STEERING WHEEL OR COLUMN REMOVAL PROCEDURES. The horn switch is mounted between the outer and inner cover of the Driver Airbag Module. When the Driver Airbag is pressed the horn switch makes contact to ground. The ground signal is carried to the horn relay and the horn sounds. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 6268 Horn Switch: Testing and Inspection The content of this article reflects changes called for in TSB 26-03-96. Horn Switch 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 Driver Airbag Module. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair 5. Using ohmmeter, connect one lead to the airbag module ground and the other lead to B+ wire. 6. Depress horn switch, and the meter should show continuity. If no continuity, replace the Driver Airbag Module. If OK, repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Locations Fuse/Fuse Block (Part 1 Of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Description and Operation Interior Lighting Relay: Description and Operation CIRCUIT OPERATION The time out relay is located in the fuse block and is used to control the ground path for various interior lamps. It will also turn the lamps OFF after a specified period of time, and works with the Remote Keyless Entry (RKE) system for illuminated entry. Circuit M2 connects to the relay and supplied a ground path through the door ajar switches. Circuit M1 is used to supply battery voltage to the relay. This circuit is produced by a 10 Amp fuse located in cavity 13 of the Power Distribution Center (PDC). Circuit M32 is connected from the relay to the various interior lamps and RKE module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Description and Operation Key Cylinder Lamp: Description and Operation CIRCUIT OPERATION The time delay relay is used to allow a time-ON function for the ignition switch halo lamp. Power for the relay is received on the M1 circuit from the 10 Amp fuse located in the Power Distribution Center (PDC). This is the Ignition-Off Draw (IOD) fuse and HOT at all times. When a door is OPENED, or the headlamp switch is moved to the dome lamp position, a ground path is provided for the relay on the M2 circuit. This energizes the relay, CLOSING the contacts. When the relay contacts are CLOSED, power is provided through the relay to the M50 circuit. The M50 circuit supplies current to the ignition switch lamp in the steering column. Ground for the lamp is provided on the Z3 circuit. This circuit splices with the glove box lamp, the ash receiver lamp, and the PRNDL lamp. The Z3 circuit terminates at the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Description and Operation > Ground Circuit License Plate Lamp: Description and Operation Ground Circuit CIRCUIT OPERATION Circuit Z1 provides ground for the tail lamps, parking lamps, headlamps, side marker lamps, lamps and rear license plate lamp although different grounding points are used. Circuit Z1 also provides the ground path for the headlamps, stop lamps and turn signals. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Description and Operation > Ground Circuit > Page 6282 License Plate Lamp: Description and Operation Tail Lamps and Rear License Plate Lamp CIRCUIT OPERATION Circuit A3 in the Power Distribution Center (PDC) connects to a bus bar in the fuse block. One of the four circuits powered by the bus bar is circuit F33. A 40 Amp fuse in the PDC protects the A3 circuit. A 15 Amp fuse, in cavity number 2 of the fuse block, protects the F33 circuit. The headlamp switch has 3 positions, ON, PARK (tail lamps) and OFF, plus a dimmer switch. Then the headlamp switch is in the PARK or ON position, it connects circuit F33 to circuit L7. From the headlamp switch, circuit L7 branches to power the front parking lamps, rear tail lamps, side marker lamps, and rear license plate lamp. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Description and Operation > Page 6283 License Plate Lamp: Testing and Inspection - Check for a blown 40 Amp fuse in the PDC. - Check for a blown fuse in cavity 2 of the fuse block - For the left rear parking lamp, turn signal, side marker lamp, and the rear license plate the Z1 circuit grounding point is in the left rear wheel well. - For the right rear parking lamp, turn signal and side marker lamp, the Z1 circuit grounding point is in the right rear wheel well. - Circuit L7 also feeds the radio, if equipped. - When the headlamp switch is in the PARK or ON position, the dimmer circuit, F33, connects to circuit E1. Circuit E1 powers the ash receiver lamp, transmission range indicator lamp, instrument panel cluster illumination lamps, HVAC control lamp, heated rear window lamp, and radio lamp. A 4 Amp fuse, in cavity 12 of the fuse block, protects circuit E1. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Component Information > Description and Operation Map Light: Description and Operation CIRCUIT OPERATION The map/reading lamps are powered by the M1 circuit from the Power Distribution Center (PDC). This circuit is the Ignition-Off Draw circuit and protected by a 10 Amp fuse. The M1 circuit is spliced and provides power for the visor/vanity lamps, radio, power mirrors. dome lamp, time delay relay, and other interior lamps. Ground for the lamps is provided from two sources. One is the Z3 circuit which is spliced in with the glove box lamp and terminates at the instrument panel left center support. The second ground is provided on circuit M2. This circuit is spliced in with the time out relay so the lamps will turn ON when any door is OPENED. On vehicles equipped with Remote Keyless Entry (RKE) the M32 circuit, which is the ground circuit when a door is OPENED, is connected to the RKE module. The module will provide a ground path for the lamps with a valid signal from the transmitter. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Description and Operation > Ground Circuit Parking Lamp: Description and Operation Ground Circuit CIRCUIT OPERATION Circuit Z1 provides ground for the parking lamps, headlamps, tail lamps, side marker lamps and rear license plate lamp although different grounding points are used. Circuit Z1 also provides the ground path for the headlamps and turn signals. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Description and Operation > Ground Circuit > Page 6291 Parking Lamp: Description and Operation Parking Lamp CIRCUIT OPERATION Circuit A3 in the Power Distribution Center (PDC) connects to a bus bar in the fuse block. One of the four circuits powered by the bus bar is circuit F33. Circuit F33 connects to the headlamp switch. A 40 Amp fuse in the PDC protects the A3 circuit. A 15 Amp fuse, in cavity 2 of the fuse block, protects the F33 circuit. The headlamp switch has 3 positions, ON, PARK (tail lamps) and OFF, plug a dimmer switch. When the headlamp switch is in the PARK or ON position, the switch connects circuit F33 to circuit L7. From the headlamp switch, circuit L7 branches to power the front parking lamps and rear tail lamps, side marker lamps, and rear license plate lamp. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Description and Operation > Page 6292 Parking Lamp: Testing and Inspection - Check for a blown 40 Amp fuse in the PDC. - Check for a blown fuse in cavity 2 of the fuse block. - For the left front parking lamp, turn signal, side marker lamp and left headlamp, the Z1 circuit grounding point is the left side of the radiator closure panel. - For the right front parking lamp, turn signal, side marker lamp and right headlamp, the Z1 circuit grounding point is in the right fender side shield. - Circuit L7 also feeds the radio, if equipped. - When the headlamp switch is in the PARK or ON position, the dimmer circuit, F33, also connects to circuit E1. Circuit E1 powers the ash receiver lamp, transmission range indicator lamp, instrument panel cluster illumination lamps, HVAC control lamp, heated rear window lamp, and radio lamp. A 4 Amp fuse, in cavity 12 of the fuse block, protects circuit E1. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Description and Operation Battery Discharge Protection Relay: Description and Operation Halo Lamp/Time Delay Relay CIRCUIT OPERATION The time delay relay is used to allow a time-ON function for the ignition switch halo lamp. Power for the relay is received on the M1 circuit from the 10 Amp fuse located in the Power Distribution Center (PDC). This is the Ignition-Off Draw (IOD) fuse and HOT at all times. When a door is OPENED, or the headlamp switch is moved to the dome lamp position, a ground path is provided for the relay on the M2 circuit. This energizes the relay, CLOSING the contacts. When the relay contacts are CLOSED, power is provided through the relay to the M50 circuit. The M50 circuit supplies current to the ignition switch lamp in the steering column. Ground for the lamp is provided on the Z3 circuit. This circuit splices with the glove box lamp, the ash receiver lamp, and the PRNDL lamp. The Z3 circuit terminates at the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation Daytime Running Lamp Control Unit: Description and Operation CIRCUIT OPERATION On vehicles built for sale in Canada, the headlamps operate, at reduced intensity, when the ignition switch is in the RUN position and the parking brake switch is OPEN. In the Power Distribution Center (PDC), a bus bar connected to battery voltage feeds circuit A1. In the RUN position, the ignition switch connects circuit A1 to circuit A21. A 30 Amp fuse in the PDC, protects circuits A1 and A21. Circuit A21 connects to a bus bar in the fuse block. The bus bar in the fuse block feeds circuit G5 through a 5 Amp fuse in cavity 11. Circuit G5 is powered only when the ignition switch is in the RUN position. Circuit G9 connects to the DRL module. The G9 circuit splices to the brake warning switch, park brake switch and instrument cluster brake warning bulb. Circuit L20 from the headlamp and dimmer switch supplies battery voltage to the DRL module at all times. Circuit A3 from the PDC feeds circuit L20. A 40 Amp fuse in the PDC protects the A3 circuit. From the DRL module, circuit L4 powers the LOW beams of the left and right headlamps. The DRL controls the power to circuit L4. Circuit L4 connects to cavity 10 of the Daytime Running Lamp (DRL) module. Circuit L3 feeds the high beams of the headlamps. When the operator flashes the headlamps with the stalk of the multi-function switch, the DRL senses voltage on circuit L3. When it senses voltage on circuit L3, the DRL module stops supplying power to the low beams on circuit L4. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Power Distribution (Part 1 Of 2) Fig. 15 Power Distribution Center (PDC) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6303 Horn Relay: Testing and Inspection The content of this article reflects changes called for in TSB 26-03-96. Horn Relay 1. Remove horn relay. 2. Using ohmmeter, test for continuity between ground and circuit 65 of horn relay. a. When the horn switch is not depressed, no continuity should be present. b. Continuity to ground when the horn switch is pdepressed. c. If continuity is not correct, repair the horn switch or wiring as necessary. 3. Insert a jumper wire between circuit 63 and 66 of the Power Distribution Center. a. If horn sounds, replace relay. b. If horn does not sound, install horn relay and refer to Horn Test. 4. Using voltmeter, test voltage at: a. Circuit 62 and 66 test for battery voltage from fuse C to body ground. b. If voltage is incorrect, repair as necessary. Refer to wiring diagrams. 5. Check relay for 70-75 ohms resistance from terminal 85 to 86. If resistance not OK, replace relay. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6304 Horn Relay: Service and Repair The content of this article reflects changes called for in TSB 26-03-96. Horn Relay 1. Remove power Distribution Center cover and locate the horn relay. 2. Remove the horn relay. Installation For installation, reverse above procedures. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations Fuse/Fuse Block (Part 1 Of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Description and Operation Interior Lighting Relay: Description and Operation CIRCUIT OPERATION The time out relay is located in the fuse block and is used to control the ground path for various interior lamps. It will also turn the lamps OFF after a specified period of time, and works with the Remote Keyless Entry (RKE) system for illuminated entry. Circuit M2 connects to the relay and supplied a ground path through the door ajar switches. Circuit M1 is used to supply battery voltage to the relay. This circuit is produced by a 10 Amp fuse located in cavity 13 of the Power Distribution Center (PDC). Circuit M32 is connected from the relay to the various interior lamps and RKE module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Transmission Connections Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6317 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6318 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6319 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6320 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6321 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6322 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6323 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6324 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6325 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6326 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6327 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6328 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6329 Backup Lamp Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6330 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6331 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6332 Rear Lighting (Part 1 Of 3) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Page 6333 Backup Lamp Switch: Testing and Inspection Back-Up Lamp Switch The back-up lamp switch circuit is through the two outside terminals of the three terminal switch. 1. To test the switch, remove the wiring connector from the switch and test for continuity between the two outside pins. Continuity should only exist with the transaxle in the REVERSE position. 2. No continuity should exist from either pin to the transaxle case. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Automatic Transmission Backup Lamp Switch: Service and Repair Automatic Transmission Park/Neutral Starting and Back-Up Lamp Switch Removal 1. Place a suitable container under the switch to catch fluid when switch is removed. 2. Unscrew switch from transaxle case allowing fluid to drain into container. 3. Move selector lever to PARK, then NEUTRAL position and inspect to see the switch operating lever fingers are centered in the switch opening. Installation 1. Crew the switch with a new seal into the transaxle case and tighten to 33 Nm (24 ft. lbs.). 2. Test switch with a test lamp. 3. Add fluid to transaxle to bring up to proper level. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Automatic Transmission > Page 6336 Backup Lamp Switch: Service and Repair Manual Transmission Back-Up Lamp Switch Removal 1. Lift vehicle on hoist. 2. From the bottom side of the vehicle, remove wiring connector from the switch. 3. Unscrew switch from the transaxle. Installation 1. To install, follow removal procedure in reverse order. Teflon tape or equivalent must be used on the switch threads. Tighten switch to 24 Nm (18 ft. lbs.). CAUTION: Do not overtighten switch. 2. Confirm back-up lamps are functioning properly following installation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6340 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6341 Brake Light Switch: Service and Repair 1. Disconnect battery ground cable. 2. Depress brake pedal and rotate switch counterclockwise approximately 30°. 3. Pull switch rearward and remove from mounting bracket. 4. Disconnect wire connector from switch. 5. Pull switch plunger head out until ratchet sound stops. 6. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps Improper Operation Door Switch: Customer Interest Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > Customer Interest for Door Switch: > 083696 > Nov > 96 > Interior Lamps Improper Operation > Page 6350 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation Door Switch: All Technical Service Bulletins Interior Lamps - Improper Operation NO: 08-36-96 GROUP: Electrical DATE: Nov. 1, 1996 SUBJECT: Interior Lights Operate Improperly After Door Adjustment MODELS: 1995 - 1997 (PL) Neon SYMPTOM/CONDITION: The interior lights operate improperly after a door has been adjusted. DIAGNOSIS: If the lights are inoperative with the doors open: ^ Begin with the left front door, open the door, the dome lamp should be on. If the dome lamp is not on, proceed to the Repair Procedure. If the dome lamp is on, repeat the check for the other doors. If the lights are on with all doors closed: ^ Begin with the left door, remove the door jam switch and disconnect the wiring connector. If the light goes off perform the Repair Procedure. If the light remains on, repeat procedure for the other doors. If all door jam switches allow the dome lamp to come on with the door open and go off with the door closed, they are operating properly and this bulletin will not correct the interior lights inoperative condition, reference the appropriate model year service manual group 8 for further diagnostics. PARTS REQUIRED: 1 04609106 Door Jam Switch REPAIR PROCEDURE: This bulletin involves the replacement of the door jam switch with an improved part. 1. Open the door with the inoperative door jam switch, Figure 1 shows the location of the drivers side door jam switch on 4 door models. 2. Remove the screw holding the switch to the vehicle. 3. Pull the switch from the vehicle and disconnect the wiring. Discard the old switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Switch: > 083696 > Nov > 96 > Interior Lamps - Improper Operation > Page 6356 4. Attach the wiring to the new door jam switch. 5. Insert the switch into the vehicle. 6. Install the screw and torque to 2 Nm (17 in. lbs.) 7. Verify proper operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-88-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch In OFF or PARKING Lamp Position Headlamp Switch: Description and Operation Headlamp Switch In OFF or PARKING Lamp Position CIRCUIT OPERATION Circuit A3 originates in the Power Distribution Center (PDC) and supplies battery voltage for the headlamp switch. A 40 Amp fuse protects the A3 circuit. The headlamp switch has an internal 24 Amp circuit breaker that connects circuit A3 to either the L2 or L20 circuits, depending on switch position. In the OFF and PARK positions the headlamp switch feeds the L20 circuit that connects to the multi-function switch. Circuit L20 powers the high beam circuit when the operator flashes the headlamps with the turn signal stalk of the multi-function switch. When the operator flashes the headlamps with the stalk, the multi-function switch connects the L20 circuit to the L3 circuit. The L3 circuit feeds the high beam of the headlamps. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch In OFF or PARKING Lamp Position > Page 6361 Headlamp Switch: Description and Operation Headlamp Switch In ON Position CIRCUIT OPERATION When the headlamp switch is in the ON position, it connects the A3 circuit from the PDC to circuit L2. Circuit L2 connects to the multi-function switch and feeds the L4 circuit (for low beam operation). The L4 circuit connects to a bus bar in the fuse block. Circuits L43 and L44 connect to the bus bar in fuse block and power the low beam headlamps. Circuit L43 supplies voltage to the left headlamp. Circuit L44 supplies voltage to the right headlamp. Both the L43 and L44 circuits have separate 10 Amp fuses located in fuse block. Fuse 17 protects circuit L43, and fuse 18 protects circuit L44. When the operator selects high beam operation with the turn signal stalk of the multi-function switch, circuit L2 connects to the L3 circuit, Circuit L3 powers high beam operation. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Page 6362 Headlamp Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove steering column cover and liner. 3. Remove three screws securing headlamp switch mounting plate to instrument panel. 4. Pull headlamp switch assembly rearward from instrument panel opening. 5. Disconnect two electrical connectors from switch. Headlamp Switch Replacement 6. Depress button on bottom of switch, then pull control knob out of switch. 7. Unsnap headlamp switch bezel from mounting plate for access to retaining nut. 8. Remove retaining nut and mounting plate from switch. 9. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Horn Switch: Locations The horn switch is part of the Driver Airbag Module. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 6366 Horn Switch: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO Restraint Systems / Air Bag Systems FOR STEERING WHEEL OR COLUMN REMOVAL PROCEDURES. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 6367 Horn Switch: Description and Operation The content of this article reflects changes called for in TSB 26-03-96. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO Restraint Systems / Air Bag Systems FOR STEERING WHEEL OR COLUMN REMOVAL PROCEDURES. The horn switch is mounted between the outer and inner cover of the Driver Airbag Module. When the Driver Airbag is pressed the horn switch makes contact to ground. The ground signal is carried to the horn relay and the horn sounds. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 6368 Horn Switch: Testing and Inspection The content of this article reflects changes called for in TSB 26-03-96. Horn Switch 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 Driver Airbag Module. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair 5. Using ohmmeter, connect one lead to the airbag module ground and the other lead to B+ wire. 6. Depress horn switch, and the meter should show continuity. If no continuity, replace the Driver Airbag Module. If OK, repair as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair Turn Signal Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove upper and lower steering column shrouds. 3. Remove combination switch mounting screws. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Description and Operation > Ground Circuit Tail Lamp: Description and Operation Ground Circuit CIRCUIT OPERATION Circuit Z1 provides ground for the tail lamps, parking lamps, headlamps, side marker lamps, lamps and rear license plate lamp although different grounding points are used. Circuit Z1 also provides the ground path for the headlamps, stop lamps and turn signals. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Description and Operation > Ground Circuit > Page 6376 Tail Lamp: Description and Operation Tail Lamps and Rear License Plate Lamp CIRCUIT OPERATION Circuit A3 in the Power Distribution Center (PDC) connects to a bus bar in the fuse block. One of the four circuits powered by the bus bar is circuit F33. A 40 Amp fuse in the PDC protects the A3 circuit. A 15 Amp fuse, in cavity number 2 of the fuse block, protects the F33 circuit. The headlamp switch has 3 positions, ON, PARK (tail lamps) and OFF, plus a dimmer switch. Then the headlamp switch is in the PARK or ON position, it connects circuit F33 to circuit L7. From the headlamp switch, circuit L7 branches to power the front parking lamps, rear tail lamps, side marker lamps, and rear license plate lamp. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Description and Operation > Page 6377 Tail Lamp: Testing and Inspection - Check for a blown 40 Amp fuse in the PDC. - Check for a blown fuse in cavity 2 of the fuse block - For the left rear parking lamp, turn signal, side marker lamp, and the rear license plate the Z1 circuit grounding point is in the left rear wheel well. - For the right rear parking lamp, turn signal and side marker lamp, the Z1 circuit grounding point is in the right rear wheel well. - Circuit L7 also feeds the radio, if equipped. - When the headlamp switch is in the PARK or ON position, the dimmer circuit, F33, connects to circuit E1. Circuit E1 powers the ash receiver lamp, transmission range indicator lamp, instrument panel cluster illumination lamps, HVAC control lamp, heated rear window lamp, and radio lamp. A 4 Amp fuse, in cavity 12 of the fuse block, protects circuit E1. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Description and Operation Trunk Lamp: Description and Operation CIRCUIT OPERATION The trunk lamp uses a case-grounded switch located on the trunk latch. The switch is normally OPEN. When the deck lid is opened, the switch CLOSES, completing a path to ground on circuit M4. The M1 circuit provides power to the lamp, and is HOT at all times. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Description and Operation > Page 6381 Trunk Lamp: Testing and Inspection - Check the 10 Amp fuse located in the Power Distribution Center (PDC) for the trunk lamp, underhood lamp, visor/Vanity lamps, dome lamp, time delay relay, and the glove box lamp. - Check for a good ground at the instrument panel left center support. - Check the door switches for a good ground. - Check the 4 Amp fuse in the fuse block, cavity 12. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Fuse/Fuse Block (Part 1 Of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Description and Operation Turn Signal Indicator: Description and Operation Right and Left Turn Signal Indicators CIRCUIT OPERATION These lamps are used to indicate to the operator which turn signal is ON. Power for the lamps comes from the turn signal switch. The L60 circuit is for the right turn indicator, and the L61 circuit is used for the left turn signal indicator. Ground for the circuits is provided on the Z3 circuit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair Turn Signal Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove upper and lower steering column shrouds. 3. Remove combination switch mounting screws. 4. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Description and Operation Vanity Lamp: Description and Operation CIRCUIT OPERATION The visor/vanity lamps are case-grounded, and are operated by a switch internal to the assembly Power for the lamps is on the M1 circuit from the Power Distribution Center (PDC). When the operator opens the cover, the switch CLOSES, completing a path to ground illuminating the lamp. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions Rear Window Defogger: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 6400 Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 6401 Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 6402 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 6403 Symbol Identification Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 6404 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 6405 Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 6406 Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 6407 Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Terminal Removal Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 6408 Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 6409 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 6410 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 6411 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 6412 Rear Window Defogger: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 6413 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Diagram Information and Instructions > Page 6414 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Page 6415 Rear Window Defogger: Description and Operation CIRCUIT OPERATION The Rear Window Defogger system is powered by a 40 Amp fuse located in the Power Distribution Center (PDC) on circuit A4. This circuit is HOT at all times. The system is also powered by a 10 Amp fuse located in cavity 8 of the fuse block, this fuse is HOT in the RUN position only. When the operator presses the rear window defogger switch the contacts internal to the switch CLOSE and the timer starts. When the switch is released the timer circuity keeps the relay energized for the specified time. Voltage is passed through the switch on the A4 circuit to the C15 circuit and then to the rear window defogger grid. The grid consists of two bus bars and grid lines that form a parallel circuit. When voltage is passed through the grid, the grid lines heat up and heat the rear window. Grounding for the rear window defogger switch is provided on the Z2 circuit and terminates at the instrument panel right center support. The grid uses the grounding point at the rear body in the right wheel house. When the system is in operation, a L.E.D. located in the switch, indicates to the operator the system is functioning. The switch is also illuminated when the headlamp switch is in the PARK or ON position. Power for the illumination circuit comes from the 4 Amp fuse, located in cavity 12 of the fuse block, on the E2 circuit. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Rear Window Defogger <--> [Heated Glass Element] > Component Information > Diagrams > Page 6416 Rear Window Defogger: Testing and Inspection - Check the 40 Amp fuse in the Power Distribution Center (PDC). - Check the 10 Amp fuse in cavity 8 of the fuse block. - Check for broken gird lines on the window. - Check for a broken buss bar or disconnected leads at the rear window. - Check for a good ground at the rear body ground located in the right rear wheel house. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Master Window Switch Power Window Switch: Description and Operation Master Window Switch Left Window Operation CIRCUIT OPERATION When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q21 circuit. The Q21 circuit connects from the switch to the left front window motor Grounding is provided on circuit Q11 from the motor back to the switch. The ground is passed through the switch to the Z8 circuit. The Z8 circuit goes to its grounding point. When window UP operation is selected, the power and ground circuits are reversed. Circuit Q11 is the feed and circuit Q21 is the ground. Right Window Operation CIRCUIT OPERATION When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q26 circuit. The Q26 circuit connects from the master switch to the right window switch. A BUS bar internal to the right switch passes the voltage through the switch to circuit Q22. Circuit Q22 connects from the switch to the right window motor. Grounding is provided on circuit Q12 from the motor back to the right switch. The ground is passed through the switch on a BUS bar to circuit Q16. Circuit Q16 then goes to the master switch. The ground is passed through the switch to the Z8 circuit. The Z8 circuit attaches to its grounding point. When window UP operation is selected, the power and ground circuits are reversed. Circuits Q12 and Q16 are the feeds and circuits Q22 and Q26 are the grounds. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Master Window Switch > Page 6422 Power Window Switch: Description and Operation Passenger Side Switch Operation CIRCUIT OPERATION When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q22 circuit. The Q22 circuit connects from the switch to the right front window motor Grounding is provided on circuit Q12 from the motor back to the switch. The ground is passed through the switch to the Q16 circuit. The Q16 circuit connects from the right switch to the master switch. Ground is passed through the master switch to the Z8 circuit. The Z8 circuit goes to its grounding point. When window UP operation is selected, the power and ground circuits are reversed. Circuit Q12 is the feed and circuit Q22 is the ground. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation > Page 6423 Power Window Switch: Testing and Inspection - Check the 40 Amp fuse located in the PDC. - Check the 30 Amp circuit breaker located behind the fuse block. - Check the ground at the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation > Master Window Switch Power Window Switch: Description and Operation Master Window Switch Left Window Operation CIRCUIT OPERATION When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q21 circuit. The Q21 circuit connects from the switch to the left front window motor Grounding is provided on circuit Q11 from the motor back to the switch. The ground is passed through the switch to the Z8 circuit. The Z8 circuit goes to its grounding point. When window UP operation is selected, the power and ground circuits are reversed. Circuit Q11 is the feed and circuit Q21 is the ground. Right Window Operation CIRCUIT OPERATION When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q26 circuit. The Q26 circuit connects from the master switch to the right window switch. A BUS bar internal to the right switch passes the voltage through the switch to circuit Q22. Circuit Q22 connects from the switch to the right window motor. Grounding is provided on circuit Q12 from the motor back to the right switch. The ground is passed through the switch on a BUS bar to circuit Q16. Circuit Q16 then goes to the master switch. The ground is passed through the switch to the Z8 circuit. The Z8 circuit attaches to its grounding point. When window UP operation is selected, the power and ground circuits are reversed. Circuits Q12 and Q16 are the feeds and circuits Q22 and Q26 are the grounds. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation > Master Window Switch > Page 6429 Power Window Switch: Description and Operation Passenger Side Switch Operation CIRCUIT OPERATION When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q22 circuit. The Q22 circuit connects from the switch to the right front window motor Grounding is provided on circuit Q12 from the motor back to the switch. The ground is passed through the switch to the Q16 circuit. The Q16 circuit connects from the right switch to the master switch. Ground is passed through the master switch to the Z8 circuit. The Z8 circuit goes to its grounding point. When window UP operation is selected, the power and ground circuits are reversed. Circuit Q12 is the feed and circuit Q22 is the ground. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation > Page 6430 Power Window Switch: Testing and Inspection - Check the 40 Amp fuse located in the PDC. - Check the 30 Amp circuit breaker located behind the fuse block. - Check the ground at the instrument panel left center support. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair REMOVAL 1. Remove door trim panel and water shield. 2. Remove inner and outer door belt weatherstrips. 3. Loosen inner belt stabilizer. 4. Lower door glass to bottom of travel to access glass attachment bolts. Regulator Lift Channel 5. Remove bolts holding regulator lift channel to door glass. Guide Bolts 6. Remove bolts holding rear guide plate to door glass. 7. Separate rear guide plate from door glass. Door Glass Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair > Page 6435 8. Lift door glass upward and out of opening at top of door. 9. Remove front guide plate from door glass. INSTALLATION 1. Install front guide plate to door glass. 2. Carefully lower door glass through opening in top of door. 3. Position rear guide plate onto door glass and install bolts. 4. Install nuts holding regulator lift channel to door glass. 5. Tighten all door glass fasteners. 6. Tighten window inner belt stabilizer. 7. Install inner and outer door belt weatherstrips. 8. Install door trim panel and water shield. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair REMOVAL 1. Remove door trim panel and water shield. 2. Remove inner door belt weatherstrip. 3. Loosen door glass jounce bumper. 4. Lower door glass to bottom of door. Rear Door Glass 5. Remove nuts holding door glass to window regulator lift plate. 6. Disengage door glass from regulator. 7. Lift door glass upward out of the opening at the top of door. INSTALLATION 1. Lower door glass through opening in top of door and into position in the window regulator. 2. Install nuts holding door glass to window regulator lift plate. 3. Raise glass and tighten window inner belt stabilizer. 4. Install inner door belt weatherstrip, watershield and door trim panel. 5. Operate window and check for interference. Adjust glass as necessary Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Front Door Window Regulator - 4 Door Window Regulator: Service and Repair Front Door Window Regulator - 4 Door NOTE: Power and manual door glass regulators are serviced using the same procedures. For power window motor service procedures, refer to Power Window Motor/Service and Repair. REMOVAL 1. Remove door trim panel and water shield. 2. Remove door glass. 3. Disconnect wire connector to power window motor, if so equipped. 4. Remove nuts holding top of regulator to inner door panel. Front Door Manual Window Regulator Front Door Power Window Regulator 5. Remove nuts holding bottom of regulator to door panel. 6. Loosen bolts holding regulator crank/motor to door panel. 7. Disengage bolts from key hole slots in door panel. 8. Remove window regulator from access hole in door panel. 9. Remove power window motor from regulator, if so equipped. Refer to Power Window Motor/Service and Repair. INSTALLATION 1. Install power window motor on regulator, if so equipped. Refer to Power Window Motor/Service and Repair. 2. Move window regulator into position in door and engage bolt heads in key-slots in inner door panel. 3. Tighten bolts attaching regulator crank/motor to door panel. 4. Install nuts holding top and bottom of window regulator to door panel. 5. Install door glass. Refer to adjustment procedures to verify and adjust glass alignment. 6. Connect wire connector to power window motor, if so equipped. 7. install door speaker, if so equipped. 8. Install door trim panel and water shield. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Front Door Window Regulator - 4 Door > Page 6443 Window Regulator: Service and Repair Rear Door Window Regulator - 4 Door REMOVAL 1. Remove door trim panel and watershield. 2. Remove door glass. 3. Loosen bolts holding window regulator crank/ motor to door panel. 4. Disengage bolt heads from keyhole slots in door panel. 5. Loosen bolts holding window regulator lift bar to door panel. Rear Door Window Regulator 6. Disengage bolt heads from keyhole slots in door panel. 7. Remove window regulator from door through access hole in inner panel. INSTALLATION 1. Move window regulator into position and engage bolt heads into key-hole slots in inner door panel. 2. Tighten bolts holding window regulator lift bar to inner door panel. 3. Engage window regulator crank/motor bolts into key-hole slots in door panel. 4. Tighten window regulator crank/motor bolts. 5. Install door glass, watershield, and door trim panel. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Front Door Window Regulator - 4 Door > Page 6444 Window Regulator: Service and Repair 2 Door Models NOTE: Power and manual door glass regulators are serviced using the same procedures. For power window motor service procedures, refer to Power Window Motor/Service and Repair. REMOVAL 1. Remove door trim panel and water shield. refer to Door Panel/Service and Repair. 2. Disconnect wire connector to power window motor, if so equipped. Regulator Lift Channel 3. Remove nuts holding regulator lift channel to door glass. 4. Secure door glass in upward position. 5. Mark position of rear bolt of roller channel to inner door panel to aid in installation. 6. Remove bolt holding rear of roller channel to door panel. 7. Loosen bolt holding front of roller channel to door panel. Roller Channel 8. Separate roller channel from door panel. 9. Loosen bolts holding window regulator to inner door panel. 10. Separate bolt heads from key-hole slots in inner door panel. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Front Door Window Regulator - 4 Door > Page 6445 Manual Window Regulator Power Window Regulator 11. Remove window regulator through large hole in inner door panel. 12. Remove power window motor from regulator, if so equipped. Refer to Power Window Motor/Service and Repair. INSTALLATION 1. Install power window motor on regulator, if so equipped. Refer to Power Window Motor/Service and Repair. 2. Move window regulator into position in door and engage bolt heads into key-hole slots in inner door panel and tighten bolts. 3. Install roller channel to door panel. 4. Install bolt at rear of roller channel. Make sure that bolt is aligned to mark on inner door panel made previously 5. Tighten front and rear bolts of roller channel. 6. Install nuts holding regulator lift channel to door glass. 7. Adjust door glass as described in this section. 8. Connect wire connector to power window motor, if so equipped. 9. Install door speaker, if so equipped. 10. Install door trim panel and water shield. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 23-46-97 > Aug > 97 > Door Glass - Scratches Technical Service Bulletin # 23-46-97 Date: 970822 Door Glass - Scratches NO: 23-46-97 GROUP: Body DATE: Aug. 22, 1997 SUBJECT: Door Glass Scratched MODELS: 1995-1997 (PL) Neon SYMPTOM/CONDITION: Door glass is scratched, inner and outer belt stabilizer contacts glass. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 23-46-97 > Aug > 97 > Door Glass - Scratches > Page 6454 Inspect the door glass, if scratch runs up the glass in line with the stabilizer location (Figure 1 & 2), perform the repair procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-30-10-96 0.7 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves the replacement of the scratched glass and inner and outer belt stabilizer assemblies. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 23-46-97 > Aug > 97 > Door Glass - Scratches > Page 6455 1. Open the door and remove the door trim panel and partial water shield to access glass fasteners. 2. Remove the inner and outer belt weatherstrip. 3. Remove the innerbelt stabilizer (figure 3). 4. Lower the door glass 3/4 way to access glass fasteners. 5. Remove the nuts holding the regulator channel to the door glass. 6. Mark (for installation) and remove the bolts holding the rear guide plate to the glass. 7. Separate the rear guide plate from the glass. 8. Lift the door glass upward and out of opening at the top of the door. 9. Remove the front guide plate from door glass. 10. Remove the outer belt stabilizer(s). If the door being repaired is the front door on the Sedan, there will be one outer belt stabilizer per door. The rear doors on the Sedan and the doors on the Coupe will have two outer belt stabilizers per door (Figure 1). 11. Install the new outer belt stabilizers using the screw and washer removed from the existing outer belt stabilizers and torque to 4.7 Nm (42 in lbs). 12. Loosely install the new window inner belt stabilizer. 13. Install the front guide plate to door glass. 14. Carefully lower the door glass through opening in top of door. 15. Position the front guide plate onto the front glass run. 16. Install the nuts holding the regulator lift channel to the door glass. 17. Use marks made in step 6 to position the rear guide plate onto door glass and install bolts. 18. Roll door glass up, adjust and tighten inner door glass stabilizer. Install inner and outer belt weatherstrips. 19. Tighten window inner and outer door belt weatherstrips. 20. Install door trim panel and water shield. 21. Adjust the door glass as needed following the procedure provided in the 1997 Neon Service Manual (Publication No. 81-270-7025) page 23-47. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Component Information > Service and Repair Window Track: Service and Repair FRONT VERTICAL GUIDE BAR 1. Remove door trim panel and water shield. 2. Remove door speaker, if equipped. 3. Remove front lift guide. 4. Remove bolt holding top of front guide bar to inner door panel. Front Vertical Guide Bar 5. Using a Snap-on (R) flare-nut socket (FRXM1O) and a hex wrench, remove nut holding bottom of guide bar to door panel while holding jack screws. Front Guide 6. Remove front vertical guide bar through speaker hole in inner door panel. 7. Reverse the preceding operation for installation. Verify door glass alignment, adjust if necessary. REAR VERTICAL GUIDE BAR 1. Remove door trim panel and water shield. 2. Remove nut holding top of rear guide bar to inner door panel. 3. Using a Snap-on (R) flare-nut socket (FRXM1O) and a hex wrench, remove nut holding bottom of guide bar to door panel while holding jack screws. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Component Information > Service and Repair > Page 6458 Rear Vertical Guide Bar 4. Remove rear vertical guide bar through large access bole in inner door panel. 5. Reverse the preceding operations and verify glass alignment. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 23-014-06 > Mar > 06 > Customer Interest for Window Seal: > 23-46-97 > Aug > 97 > Door Glass - Scratches Technical Service Bulletin # 23-46-97 Date: 970822 Door Glass - Scratches NO: 23-46-97 GROUP: Body DATE: Aug. 22, 1997 SUBJECT: Door Glass Scratched MODELS: 1995-1997 (PL) Neon SYMPTOM/CONDITION: Door glass is scratched, inner and outer belt stabilizer contacts glass. DIAGNOSIS: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 23-014-06 > Mar > 06 > Customer Interest for Window Seal: > 23-46-97 > Aug > 97 > Door Glass - Scratches > Page 6468 Inspect the door glass, if scratch runs up the glass in line with the stabilizer location (Figure 1 & 2), perform the repair procedure. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-30-10-96 0.7 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves the replacement of the scratched glass and inner and outer belt stabilizer assemblies. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 23-014-06 > Mar > 06 > Customer Interest for Window Seal: > 23-46-97 > Aug > 97 > Door Glass - Scratches > Page 6469 1. Open the door and remove the door trim panel and partial water shield to access glass fasteners. 2. Remove the inner and outer belt weatherstrip. 3. Remove the innerbelt stabilizer (figure 3). 4. Lower the door glass 3/4 way to access glass fasteners. 5. Remove the nuts holding the regulator channel to the door glass. 6. Mark (for installation) and remove the bolts holding the rear guide plate to the glass. 7. Separate the rear guide plate from the glass. 8. Lift the door glass upward and out of opening at the top of the door. 9. Remove the front guide plate from door glass. 10. Remove the outer belt stabilizer(s). If the door being repaired is the front door on the Sedan, there will be one outer belt stabilizer per door. The rear doors on the Sedan and the doors on the Coupe will have two outer belt stabilizers per door (Figure 1). 11. Install the new outer belt stabilizers using the screw and washer removed from the existing outer belt stabilizers and torque to 4.7 Nm (42 in lbs). 12. Loosely install the new window inner belt stabilizer. 13. Install the front guide plate to door glass. 14. Carefully lower the door glass through opening in top of door. 15. Position the front guide plate onto the front glass run. 16. Install the nuts holding the regulator lift channel to the door glass. 17. Use marks made in step 6 to position the rear guide plate onto door glass and install bolts. 18. Roll door glass up, adjust and tighten inner door glass stabilizer. Install inner and outer belt weatherstrips. 19. Tighten window inner and outer door belt weatherstrips. 20. Install door trim panel and water shield. 21. Adjust the door glass as needed following the procedure provided in the 1997 Neon Service Manual (Publication No. 81-270-7025) page 23-47. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair Window Track: Service and Repair FRONT VERTICAL GUIDE BAR 1. Remove door trim panel and water shield. 2. Remove door speaker, if equipped. 3. Remove front lift guide. 4. Remove bolt holding top of front guide bar to inner door panel. Front Vertical Guide Bar 5. Using a Snap-on (R) flare-nut socket (FRXM1O) and a hex wrench, remove nut holding bottom of guide bar to door panel while holding jack screws. Front Guide 6. Remove front vertical guide bar through speaker hole in inner door panel. 7. Reverse the preceding operation for installation. Verify door glass alignment, adjust if necessary. REAR VERTICAL GUIDE BAR 1. Remove door trim panel and water shield. 2. Remove nut holding top of rear guide bar to inner door panel. 3. Using a Snap-on (R) flare-nut socket (FRXM1O) and a hex wrench, remove nut holding bottom of guide bar to door panel while holding jack screws. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Page 6473 Rear Vertical Guide Bar 4. Remove rear vertical guide bar through large access bole in inner door panel. 5. Reverse the preceding operations and verify glass alignment. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection Wiper Switch: Testing and Inspection Fig.9 Wiper Switch Tests 1. Disconnect wiper switch wiring from main wiring at steering column. 2. Using a suitable ohmmeter test continuity between connector pins as shown. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 6479 Wiper Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove three screws from steering column shroud and remove upper half of shroud. 3. Remove mounting screws on switch and remove switch. 4. Disconnect electrical connector from switch. 5. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Technical Service Bulletins > Customer Interest: > 081196 > Apr > 96 > Windshield Washers - Delayed Washer Fluid Output Windshield Washer Hose: Customer Interest Windshield Washers - Delayed Washer Fluid Output NO: 08-11-96 GROUP: Electrical DATE: Apr. 12, 1996 SUBJECT: Delayed Washer Fluid Output MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Delayed washer fluid output from one or both washer nozzles when wash button is depressed. PARTS REQUIRED: 2 4805010 Check Valve, Windshield Washer REPAIR PROCEDURE: This bulletin involves the installation of a new windshield washer hose check valve at the nozzle. 1. Disconnect both washer hoses from the washer nozzle. 2. Remove the check valve from one hose. 3. Install the new check valve (white in color) (P/N 4805010) with the end housing the check ball toward the reservoir and the open end toward the nozzle. 4. Repeat steps 2 and 3 for the other side. 5. Connect the hose/check valve assemblies to the nozzle. 6. Verify proper windshield washer operation. If the fluid does not flow properly, check the hose to insure there are no kinks or pinched areas and insure check valve is installed in the proper direction. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-43-14-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 081196 > Apr > 96 > Windshield Washers - Delayed Washer Fluid Output Windshield Washer Hose: All Technical Service Bulletins Windshield Washers - Delayed Washer Fluid Output NO: 08-11-96 GROUP: Electrical DATE: Apr. 12, 1996 SUBJECT: Delayed Washer Fluid Output MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION: Delayed washer fluid output from one or both washer nozzles when wash button is depressed. PARTS REQUIRED: 2 4805010 Check Valve, Windshield Washer REPAIR PROCEDURE: This bulletin involves the installation of a new windshield washer hose check valve at the nozzle. 1. Disconnect both washer hoses from the washer nozzle. 2. Remove the check valve from one hose. 3. Install the new check valve (white in color) (P/N 4805010) with the end housing the check ball toward the reservoir and the open end toward the nozzle. 4. Repeat steps 2 and 3 for the other side. 5. Connect the hose/check valve assemblies to the nozzle. 6. Verify proper windshield washer operation. If the fluid does not flow properly, check the hose to insure there are no kinks or pinched areas and insure check valve is installed in the proper direction. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-43-14-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield Washer Hose: > 23-014-06 > Mar > 06 > Wipers/Washers Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers Wiper Motor: Testing and Inspection Standard Wipers Important Information - Read First Whenever a wiper motor malfunction occurs, first ensure wiper motor wire harness is properly connected before starting with normal diagnosis and repair procedures. Motor Will Not Operate In Some or All Switch Positions 1. Check fuse No. 15 in fuse block: a. If fuse is OK proceed to next step. b. If fuse is bad, replace, then check wiper functions in all switch positions. If fuse blows again, proceed to voltmeter test step below. c. If replaced fuse does not blow and motor does not run, proceed to next step. Fig.7 Wiper Motor Connector 2. Disconnect motor connector, and perform the following tests: a. Connect jumper wire from battery negative terminal to motor ground strap. b. Connect jumper wire from battery positive terminal to pin two of connector, then move jumper wire from battery positive terminal to pin one of connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6520 Fig.8 Wiper System Wiring Diagram (Part 1 of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6521 Fig.8 Wiper System Wiring Diagram (Part 2 of 2) c. If motor runs OK check wiring circuits. Check wiper switch. d. If motor does not run proceed to next step. 3. Using a suitable ohmmeter check ground strap at motor: a. If ground strap is OK, replace motor. b. If not OK, repair ground as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6522 4. Using a suitable voltmeter, with wiper switch connected: Fig.9 Wiper Switch Tests a. Connect voltmeter positive lead to terminal P1, and negative lead to motor ground. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6523 Fig.8 Wiper System Wiring Diagram (Part 1 of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6524 Fig.8 Wiper System Wiring Diagram (Part 2 of 2) b. If no voltage, repair wiring circuits as necessary. c. If voltage is OK, connect voltmeter positive lead to wiper switch terminal L, then move switch to low speed position. If no voltage replace switch. d. Repeat above test for wiper switch terminal H. e. If all tests OK, proceed to next step. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6525 5. Disconnect motor connector, then replace fuse fifteen in fuse block: a. If fuse does not blow, replace motor. b. If fuse blows, disconnect wiper switch and replace fuse fifteen in fuse block. c. If fuse does not blow replace switch. Fig.8 Wiper System Wiring Diagram (Part 1 of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6526 Fig.8 Wiper System Wiring Diagram (Part 2 of 2) d. If fuse blows, check and repair wiring circuits, as necessary. Wipers Do Not Operate In Washer or Pulse Mode Using a suitable ohmmeter check motor ground, if OK replace wiper switch. If not OK, repair ground. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6527 Wipers Operate Slowly at All Speeds Refer to Testing and Inspection/Procedures/Inspection See: Wiper Motor Runs Slow Wipers Run Fast In Low Position or Slow In Fast Position Fig.8 Wiper System Wiring Diagram (Part 1 of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6528 Fig.8 Wiper System Wiring Diagram (Part 2 of 2) 1. Check for crossed wires in wiper motor connectors. 2. Check for crossed wires in wiper switch connectors. 3. If OK replace wiper switch. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6529 Wiper Motor: Testing and Inspection Intermittent Wiper System Important Information - Read First The intermittent wipe function is controlled by the body controller, located in the passenger compartment behind the right side kick panel. To diagnose system malfunctions that do not involve the delay function, refer to "Standard Front Wipers" in this section. Motor Will Not Operate In Some or All Switch Positions 1. Check fuse fifteen in fuse block: a. If fuse is OK proceed to next step. b. If fuse is bad, replace, then check wiper functions in all switch positions. If fuse blows again proceed to voltmeter test step below. c. If replaced fuse does not blow and motor does not run, proceed to next step. Fig.7 Wiper Motor Connector 2. Disconnect motor connector, perform the following tests: a. Connect jumper wire from battery negative terminal to motor ground strap. b. Connect jumper wire from battery positive terminal to pin two of connector, then move jumper wire from battery positive terminal to pin one of connector. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6530 Fig.8 Wiper System Wiring Diagram (Part 1 of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6531 Fig.8 Wiper System Wiring Diagram (Part 2 of 2) c. If motor runs OK, check wiring circuits, and wiper switch as outlined under "Component Diagnosis & Testing." d. If motor does not run, proceed to next step. 3. Using a suitable ohmmeter, check ground strap at motor as follows: a. If ground strap is OK, replace motor. b. If not OK, repair ground as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6532 Fig.9 Wiper Switch Tests 4. Using a suitable ohmmeter, check continuity from terminal E of wiper switch, to ground: a. If OK, proceed to next step. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6533 Fig.8 Wiper System Wiring Diagram (Part 1 of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6534 Fig.8 Wiper System Wiring Diagram (Part 2 of 2) b. If not OK, repair wiring circuit to ground. 5. Using a suitable voltmeter, with wiper switch connected: a. Connect voltmeter positive lead to terminal P1, and negative lead to motor ground. b. If no voltage, repair wiring circuits as necessary. c. If voltage is OK, connect voltmeter positive lead to wiper switch terminal L, then move switch to low speed position. If no voltage replace Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6535 switch. d. Repeat above test for wiper switch terminal H. e. If all tests OK, proceed to next step. 6. Disconnect motor connector, then replace fuse fifteen in fuse block: a. If fuse does not blow, replace motor. b. If fuse blows, disconnect wiper switch and replace fuse fifteen in fuse block. c. If fuse does not blow replace switch. d. If fuse blows, check and repair wiring circuits, as necessary. Runs Continuously In Intermittent Mode/Will Not "Park" Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6536 Fig.8 Wiper System Wiring Diagram (Part 1 of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6537 Fig.8 Wiper System Wiring Diagram (Part 2 of 2) 1. Using a suitable ohmmeter, check motor ground and repair if necessary. 2. With ignition switch in OFF position and wiper motor in park position: Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6538 Fig.7 Wiper Motor Connector a. Using a suitable ohmmeter, check for continuity between pin three of wiper motor connector, and ground. b. If OK, replace wiper switch. c. If not OK, repair wiring circuits as necessary. Wipers Do Not Operate In Washer, Pulse or Intermittent Mode Fig.9 Wiper Switch Tests Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6539 Fig.8 Wiper System Wiring Diagram (Part 1 of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6540 Fig.8 Wiper System Wiring Diagram (Part 2 of 2) 1. Using a suitable ohmmeter, check motor ground and continuity from terminal E of wiper switch, to ground. 2. If OK, replace wiper switch. 3. If not OK, repair wiring circuit as necessary. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6541 Wiper Motor: Testing and Inspection Wiper Motor Runs Slow 1. Remove wiper arms and cowl panel. 2. Disconnect wiper linkage and wiring connector from motor. Fig.82 Wiper Motor Current Test 3. Connect a suitable ammeter between motor and battery positive terminal. 4. With motor running, if current draw is greater than six amps, check for binding in shafts and linkage. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6542 Fig.8 Wiper System Wiring Diagram (Part 1 of 2) Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Standard Wipers > Page 6543 Fig.8 Wiper System Wiring Diagram (Part 2 of 2) 5. With motor running, if current draw is less than six amps, use a suitable ohmmeter and check wiper circuits for short to ground. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Page 6544 Wiper Motor: Service and Repair 1. Disconnect battery ground cable. 2. Remove wiper arms and blades. 3. Remove rear hood seal and cowl screen. 4. Remove electrical connector at wiper motor. 5. Remove mounting screws from wiper assembly. 6. Disconnect wiper linkage from bellcrank on wiper motor. 7. Reverse procedure to install. Dodge Neon Workshop Manual (L4-2.0L DOHC (1996)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection Wiper Switch: Testing and Inspection Fig.9 Wiper Switch Tests 1. Disconnect wiper switch wiring from main wiring at steering column. 2. Using a suitable ohmmeter test continuity between connector pins as shown.